Battery

ABSTRACT

A battery includes a first electrode layer; and another electrode layer disposed on the first electrode layer and serving as a counter electrode for the first electrode layer. The first electrode layer includes a first current collector, a first active material layer, and a first solid electrolyte layer. The first active material layer is disposed to be in contact with the first current collector and to occupy a smaller area than the first current collector. The first solid electrolyte layer is disposed to be in contact with the first current collector and the first active material layer and to occupy the same area as the first current collector. The first electrode layer includes a peripheral portion including a first rounded portion, and the another electrode layer includes a peripheral portion including another rounded portion.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of U.S. patent application Ser. No.16/868,167, filed May 6, 2020, which is a Division of U.S. patentapplication Ser. No. 15/956,718, filed Apr. 18, 2018, now U.S. Pat. No.10,686,213, issued on Jun. 16, 2020, which claims the benefit ofJapanese Application No. 2017-098681, filed May 18, 2017. The disclosureof each of the above-identified applications, including thespecification, drawings, and claims, is incorporated herein by referencein its entirety.

BACKGROUND 1. Technical Field

The present disclosure relates to a battery.

2. Description of the Related Art

Japanese Unexamined Patent Application Publication No. 2010-056067discloses a battery in which a current collector, a positive electrode,a solid electrolyte, and a negative electrode have substantially thesame disc shape.

Japanese Unexamined Patent Application Publication No. 2013-229315discloses a coin battery in which a solid electrolyte layer covers theedge portion of a positive electrode current collector and the edgeportion of a positive electrode active material layer.

Japanese Unexamined Patent Application Publication No. 2000-149994discloses a battery in which a positive electrode, a negative electrode,and an electrolyte layer have round corner portions.

SUMMARY

In the related art, a reduction in the probability of coming off ofactive material is desirably achieved.

In one general aspect, the techniques disclosed here feature a batteryincluding: a first electrode layer; and a second electrode layerdisposed on the first electrode layer and serving as a counter electrodefor the first electrode layer, wherein the first electrode layerincludes a first current collector, a first active material layer, and afirst solid electrolyte layer, the first active material layer isdisposed to be in contact with the first current collector and to occupya smaller area than the first current collector, the first solidelectrolyte layer is disposed to be in contact with the first currentcollector and the first active material layer and to occupy the samearea as the first current collector, the first active material layerfaces the second electrode layer with the first solid electrolyte layertherebetween, and the first electrode layer includes a peripheralportion including a first rounded portion.

The present disclosure enables a reduction in the probability of comingoff of active material.

Additional benefits and advantages of the disclosed embodiments willbecome apparent from the specification and drawings. The benefits and/oradvantages may be individually obtained by the various embodiments andfeatures of the specification and drawings, which need not all beprovided in order to obtain one or more of such benefits and/oradvantages.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates the schematic configuration of a battery 1000according to Embodiment 1;

FIG. 2 illustrates the schematic configuration of a battery 1100according to Embodiment 1;

FIG. 3 illustrates the schematic configuration of a battery 1200according to Embodiment 1;

FIG. 4 illustrates the schematic configuration of a battery 1300according to Embodiment 1;

FIGS. 5A to 5E are x-y views (top perspective views) of other exampleshapes of a first current collector 110 and a first active materiallayer 120;

FIG. 6 illustrates the schematic configuration of a battery 1400according to Embodiment 1;

FIG. 7 illustrates the schematic configuration of a battery500 accordingto Embodiment 1;

FIG. 8 illustrates the schematic configuration of a battery 1600according to Embodiment 1;

FIG. 9 illustrates the schematic configuration of a battery 1700according to Embodiment 1;

FIG. 10 illustrates the schematic configuration of a battery 2000according to Embodiment 2;

FIG. 11 illustrates the schematic configuration of a battery 2100according to Embodiment 2;

FIG. 12 illustrates the schematic configuration of a battery2200according to Embodiment 2;

FIG. 13 illustrates the schematic configuration of a battery 2300according to Embodiment 2;

FIG. 14 illustrates the schematic configuration of a battery 3000according to Embodiment 3;

FIG. 15 illustrates the schematic configuration of a battery 00according to Embodiment 3;

FIG. 16 illustrates the schematic configuration of a battery 200according to Embodiment 3;

FIG. 17 illustrates the schematic configuration of a battery 4000according to Embodiment 4;

FIG. 18 is an x-z view (sectional view) illustrating the schematicconfiguration of a battery 4100 according to Embodiment 4;

FIG. 19 is an x-z view (sectional view) illustrating the schematicconfiguration of a battery 4200 according to Embodiment 4;

FIG. 20 illustrates the schematic configuration of a battery 5000according to Embodiment 5;

FIG. 21 is an x-z view (sectional view) illustrating the schematicconfiguration of a battery 5100 according to Embodiment 5;

FIG. 22 is an x-z view (sectional view) illustrating the schematicconfiguration of a battery 5200 according to Embodiment 5;

FIG. 23 illustrates the schematic configuration of a batterymanufacturing apparatus 6000 according to Embodiment 6;

FIG. 24 is a flowchart illustrating a battery manufacturing methodaccording to Embodiment 6;

FIG. 25 illustrates an example of a first-active-material-layerformation step S1110 and a first-solid-electrolyte-layer formation stepS1120;

FIG. 26 illustrates an example of a second-active-material-layerformation step S1210 and a second-solid-electrolyte-layer formation stepS1220;

FIG. 27 illustrates an example of a layer disposition step S1310;

FIG. 28 is a flowchart illustrating a modification of a batterymanufacturing method according to Embodiment 6;

FIG. 29 illustrates the schematic configuration of a batteryanufacturingapparatus 6100 according to Embodiment 6;

FIG. 30 is a flowchart illustrating a modification of a batterymanufacturing method according to Embodiment 6;

FIG. 31 illustrates an example of a first-solid-electrolyte-layerformation step S1121 and a first-electrode-side cutting step S1122;

FIG. 32 illustrates an example of a second-solid-electrolyte-layerformation step 51221 and a second-electrode-side cutting step S1222;

FIG. 33 illustrates the schematic configuration of a batterymanufacturing apparatus 7000 according to Embodiment 7;

FIG. 34 is a flowchart illustrating a battery manufacturing methodaccording to Embodiment 7;

FIG. 35 illustrates an example of a first-active-material-layerformation step S2110 and a first-solid-electrolyte-layer formation stepS2120;

FIG. 36 illustrates an example of a second-active-material-layerformation step S2210 and a second-solid-electrolyte-layer formation stepS2220;

FIG. 37 illustrates an example of a layer disposition step S2310;

FIG. 38 illustrates an example of a cutting step S2510; and

FIG. 39 is a flowchart illustrating a modification of a batterymanufacturing method according to Embodiment 7.

DETAILED DESCRIPTION

Hereinafter, embodiments according to the present disclosure will bedescribed with referring to the drawings.

Embodiment 1

FIG. 1 illustrates the schematic configuration of a battery 1000according to Embodiment 1.

FIG. 1(a) is an x-z view (sectional view taken along line 1A-1A)illustrating the schematic configuration of the battery 1000 accordingto Embodiment 1.

FIG. 1(b) is an x-y view (top perspective view) illustrating theschematic configuration of the battery 1000 according to Embodiment 1.

The battery 1000 according to Embodiment 1 includes a first electrodelayer 100 and a second electrode layer 200.

The second electrode layer 200 is disposed on the first electrode layer100. The second electrode layer 200 serves as a counter electrode forthe first electrode layer 100.

The first electrode layer 100 includes a first current collector 110, afirst active material layer 120, and a first solid electrolyte layer130.

The first active material layer 120 is disposed to be in contact withthe first current collector 110, and to occupy a smaller area than thefirst current collector 110.

The first solid electrolyte layer 130 is disposed to be in contact withthe first current collector 110 and the first active material layer 120,and to occupy the same area as the first current collector 110.

The first active material layer 120 faces the second electrode layer 200with the first solid electrolyte layer 130 therebetween.

The first electrode layer 100 includes a peripheral portion including afirst rounded portion 140.

Such a configuration enables a reduction in the probability of comingoff of the active material. Specifically, use of the first electrodelayer 100, which includes a peripheral portion including the firstrounded portion 140, enables a reduction in concentration of stress inthe peripheral portion including the first rounded portion 140 in themultilayer body including the first current collector 110 and the firstsolid electrolyte layer 130 (for example, dispersion of an impactforce). This enables, in the peripheral portion including the firstrounded portion 140, a reduction in the probability of separation of thefirst solid electrolyte layer 130 from the first current collector 110(or falling of the solid electrolyte from the first current collector110). Thus, the first solid electrolyte layer 130, which is less likelyto separate from the first current collector 110, is disposed to coverthe first active material layer 120. As a result, for example, even whena corner of the battery being manufactured or used collides and impacts,the first solid electrolyte layer 130 enables a reduction in the damagecaused on the first active material layer 120. In other words, the firstsolid electrolyte layer 130 enables a reduction in the probability ofcoming off of the active material from the first active material layer120. This prevents short circuits within the battery that may be causedby movements of, within the battery, the active material coming off fromthe first active material layer 120. This enables enhanced reliabilityof the battery.

In the above-described configuration, the first solid electrolyte layer130, which is less likely to separate from the first current collector110, is disposed to cover the first active material layer 120. In thiscase, even when the first active material layer 120 is disposed toextend close to the peripheral portion of the first current collector110, the active material is prevented from coming off from the firstactive material layer 120. Thus, the first active material layer 120 canbe disposed to occupy an area as large as possible, provided that thearea is smaller than that of the first current collector 110. Thisenables an increase in the energy density of the battery.

In the present disclosure, the phrase “the solid electrolyte layer isdisposed to occupy the same area as the current collector” means thatthe solid electrolyte layer is disposed to occupy substantially the samearea as the current collector except for the error unavoidably occurringduring the manufacture (for example, the solid electrolyte layer isdisposed to have substantially the same shape as the current collectorexcept for the error unavoidably occurring during the manufacture).

Incidentally, as illustrated in FIG. 1, the second electrode layer 200may include a second current collector 210, a second active materiallayer 220, and a second solid electrolyte layer 230.

The second active material layer 220 is disposed to be in contact withthe second current collector 210.

The second solid electrolyte layer 230 is disposed to be in contact withthe second active material layer 220.

The second active material layer 220 faces the first active materiallayer 120 with the first solid electrolyte layer 130 and the secondsolid electrolyte layer 230 therebetween.

Such a configuration enables a reduction in the probability of contactbetween the first current collector 110 and the second current collector210. Specifically, a portion between the first current collector 110 andthe second current collector 210, which face each other with the portiontherebetween, is fixed with the first solid electrolyte layer 130 andthe second solid electrolyte layer 230. For example, even when the firstcurrent collector 110 and the second current collector 210 areconstituted by thin films, the presence of the first solid electrolytelayer 130 and the second solid electrolyte layer 230 enables the spacingbetween the first current collector 110 and the second current collector210 to be maintained to have at least a predetermined distance (forexample, equal to or longer than the total thickness of the first solidelectrolyte layer 130 and the second solid electrolyte layer 230). Thisprevents the first current collector 110 and the second currentcollector 210 from coming into close proximity to each other. Thisprevents, for example, even when a plurality of battery cells arestacked, deformation of the first current collector 110 and the secondcurrent collector 210. Thus, for example, even when a plurality ofbattery cells are stacked, short circuits are prevented between thefirst current collector 110 and the second current collector 210. Inaddition, in another example that is an all-solid-state battery nothaving any separator between the first electrode layer 100 and thesecond electrode layer 200, the risk of short circuits caused by directcontact between the first current collector 110 and the second currentcollector 210 is reduced.

In addition, the above-described configuration eliminates the necessityof an additional member for insulation between the first electrode layer100 and the second electrode layer 200 (for example, an insulationspacer). This enables further simplification of and a reduction in thecosts for battery manufacturing steps.

Incidentally, the first solid electrolyte layer 130 and the second solidelectrolyte layer 230 may be bonded together.

In such a configuration, the solid electrolyte layer provided by bondingtogether the first solid electrolyte layer 130 and the second solidelectrolyte layer 230 enables a reduction in the probability of shortcircuits due to pinholes that may be formed, for example, duringmanufacture, in the first solid electrolyte layer 130 and the secondsolid electrolyte layer 230. More specifically, in a region where thefirst active material layer 120 and the second active material layer 220face each other, a bonding interface is provided that is formed bybonding together the first solid electrolyte layer 130 and the secondsolid electrolyte layer 230. In this case, the first solid electrolytelayer 130 and the second solid electrolyte layer 230 are each formed bya different manufacturing step, so that the positions of pinholesgenerated in the first solid electrolyte layer 130 do not coincide withthe positions of pinholes generated in the second solid electrolytelayer 230. Thus, the second solid electrolyte layer 230 blocks, at thebonding interface, the pinholes generated in the first solid electrolytelayer 130. The first solid electrolyte layer 130 blocks, at the bondinginterface, the pinholes generated in the second solid electrolyte layer230. This enables a reduction in the probability of short circuits dueto pinholes that may be generated during manufacture in the solidelectrolyte layers.

Incidentally, as illustrated in FIG. 1, a partial region of a mainsurface (for example, a half or larger region of the main surface) ofthe first solid electrolyte layer 130 and the whole region of a mainsurface of the second solid electrolyte layer 230 may be bondedtogether. Alternatively, a partial region of a main surface (forexample, a half or larger region of the main surface) of the first solidelectrolyte layer 130 and a partial region of a main surface (forexample, a half or larger region of the main surface) of the secondsolid electrolyte layer 230 may be bonded together. Alternatively, thewhole region of a main surface of the first solid electrolyte layer 130and the whole region of a main surface of the second solid electrolytelayer 230 may be bonded together.

The first active material layer 120 contains an electrode material (forexample, an active material).

The second active material layer 220 contains a counter electrodematerial (for example, an active material). The counter electrodematerial constitutes the counter electrode for the above-describedelectrode material.

The first solid electrolyte layer 130 and the second solid electrolytelayer 230 are solid electrolyte layers containing solid electrolytes.

Incidentally, the first active material layer 120 may be a negativeelectrode active material layer. In this case, the electrode material isa negative electrode active material. The first current collector 110 isa negative electrode current collector. The first solid electrolytelayer 130 is a negative-electrode-side solid electrolyte layer. Thesecond active material layer 220 is a positive electrode active materiallayer. The counter electrode material is a positive electrode activematerial. The second current collector 210 is a positive electrodecurrent collector. The second solid electrolyte layer 230 is apositive-electrode-side solid electrolyte layer.

Alternatively, the first active material layer 120 may be a positiveelectrode active material layer. In this case, the electrode material isa positive electrode active material. The first current collector 110 isa positive electrode current collector. The first solid electrolytelayer 130 is a positive-electrode-side solid electrolyte layer. Thesecond active material layer 220 is a negative electrode active materiallayer. The counter electrode material is a negative electrode activematerial. The second current collector 210 is a negative electrodecurrent collector. The second solid electrolyte layer 230 is anegative-electrode-side solid electrolyte layer.

The positive electrode current collector may be selected from publiclyknown positive electrode current collectors. The positive electrodecurrent collector may be, for example, a metal foil. Examples of thematerial of the positive electrode current collector include aluminum,copper, stainless steel, nickel, platinum, gold, and alloys containingthe foregoing.

The positive electrode active material layer contains a positiveelectrode active material.

The positive electrode active material may be selected from publiclyknown positive electrode active materials. When the battery 1000according to Embodiment 1 is constituted as a lithium ion secondarybattery (storage battery), the positive electrode active material may bea compound that has a capability of occluding and releasing Li. Forexample, the positive electrode active material may be a compoundcontaining lithium. Examples of the positive electrode active materialinclude LiCoO₂, LiNiO₂, LiMn₂O₄, LiCoPO₄, LiMnPO₄, LiFePO₄, LiNiPO₄, andcompounds obtained by substituting the transition metal of such acompound by one or two hetero elements (for example,LiNi_(1/3)Co_(1/3)Mn_(1/3)O₂, LiNi_(0.8)Co_(0.15)Al_(0.05)O₂, andLiNi_(0.5)Mn_(1.5)O₂).

Incidentally, the positive electrode active material layer may be apositive electrode mixture layer containing a positive electrode activematerial and another material. Specifically, the positive electrodeactive material layer may contain a mixture of a positive electrodeactive material and a solid electrolyte. Alternatively, the positiveelectrode active material layer may contain, in addition to a positiveelectrode active material and a solid electrolyte, a conductive additiveor a binder, for example.

The positive electrode active material layer may be constituted by aplurality of layers. For example, the positive electrode active materiallayer may include, on its side in contact with the positive electrodecurrent collector, a first layer. In this case, the positive electrodeactive material layer may include, on its side in contact with thepositive-electrode-side solid electrolyte layer, a second layer. In thiscase, the first layer and the second layer may be different from eachother in terms of constitutions (shape, thickness, and containedmaterial).

The positive-electrode-side solid electrolyte layer contains apositive-electrode-side solid electrolyte.

The positive-electrode-side solid electrolyte may be selected frompublicly known solid electrolytes. When the battery 1000 according toEmbodiment 1 is constituted as a lithium ion secondary battery (storagebattery), the solid electrolyte may be a compound containing lithium.Examples of the solid electrolyte include Li₃Zr₂Si₂PO₁₂, Li₇La₃Zr₂O₁₂,Li₅La₃Ta₂O₁₂, Li_(1+x)Al_(x)Ti_(2-x)(PO₄)₃,Li_(1.5)Ti_(1.7)Al_(0.8)P_(2.5)Si_(0.2)O₁₂, La_(2/3-x)Li_(3x)TiO₃,Li₂S-SiS₂-based glass and glass ceramics, Li₂S-B₂S₃-based glass andglass ceramics, Li₂S-P₂S₅-based glass and glass ceramics,Li_(3.25)Ge_(0.25)P_(0.75)S₄, and Li₁₀GeP₂S₁₂. Other examples of thesolid electrolyte include solid electrolytes obtained by adding anadditive such as LiI or Li_(x)MO_(y) (M: P, Si, Ge, B, Al, Ga, or In; x,y: natural numbers) to the above-described examples. Examples of thesolid electrolyte include inorganic solid electrolytes (sulfide solidelectrolytes or oxide solid electrolytes) and polymer solid electrolytes(for example, electrolytes obtained by dissolving a lithium salt inpolyethylene oxide).

The positive-electrode-side solid electrolyte layer may be formed of apolymer electrolyte or a mixture of an inorganic solid electrolyte and abinder. In the positive-electrode-side solid electrolyte layer and thepositive electrode active material layer, the solid electrolytes may beformed of the same material and the binders may be formed of the samematerial.

The negative electrode current collector may be selected from publiclyknown negative electrode current collectors. The negative electrodecurrent collector may be, for example, a metal foil. Examples of thematerial of the negative electrode current collector include aluminum,copper, stainless steel, nickel, platinum, gold, and alloys containingthe foregoing.

The negative electrode active material layer contains a negativeelectrode active material.

The negative electrode active material may be selected from publiclyknown negative electrode active materials. When the battery 1000according to Embodiment 1 is constituted as a lithium ion secondarybattery (storage battery), the negative electrode active material may bea compound that has a capability of occluding and releasing Li. Forexample, the negative electrode active material may be a metal compoundor a carbonaceous material. Examples of the negative electrode activematerial include metal indium, metal lithium, carbonaceous materials(for example, graphite or hard carbon), Li₄Ti₅O₁₂, Si, SiO, Sn, and SnO.

Incidentally, the negative electrode active material layer may be anegative electrode mixture layer containing a negative electrode activematerial and another material. Specifically, the negative electrodeactive material layer may contain a mixture of a negative electrodeactive material and a solid electrolyte. Alternatively, the negativeelectrode active material layer may contain, in addition to a negativeelectrode active material and a solid electrolyte, a conductive additiveor a binder, for example. Incidentally, when the negative electrodeactive material layer is constituted by a foil formed of a metal thatalloys with lithium, addition of the solid electrolyte and the like isnot necessary.

The negative-electrode-side solid electrolyte layer contains anegative-electrode-side solid electrolyte.

The negative electrode active material layer may be constituted by aplurality of layers. For example, the negative electrode active materiallayer may include, on its side in contact with the negative electrodecurrent collector, a first layer. In this case, the negative electrodeactive material layer may include, on its side in contact with thenegative-electrode-side solid electrolyte layer, a second layer. In thiscase, the first layer and the second layer may be different from eachother in terms of constitutions (shape, thickness, and containedmaterial).

The negative-electrode-side solid electrolyte may be selected frompublicly known solid electrolytes. Examples of the material of thenegative-electrode-side solid electrolyte include the above-describedexamples of the material of the positive-electrode-side solidelectrolyte.

The negative-electrode-side solid electrolyte layer may be formed of apolymer electrolyte or a mixture of an inorganic solid electrolyte and abinder. In the negative-electrode-side solid electrolyte layer and thenegative electrode active material layer, the solid electrolytes may beformed of the same material and the binders may be formed of the samematerial.

Examples of the conductive additives include carbonaceous materials (forexample, acetylene black, Ketjenblack, or carbon nanotubes), and metalpowders.

The binders may be selected from publicly known polymer compounds.Examples of the binders include polyvinylidene fluoride (PVDF),polyvinylidene fluoride-hexafluoropropylene (PVDF-HFP), rubber-basedresins, and elastomers.

Incidentally, the positive-electrode-side solid electrolyte layer andthe negative-electrode-side solid electrolyte layer may both contain asolid electrolyte of the same material, or may each contain a solidelectrolyte of a different material.

The positive-electrode-side solid electrolyte layer and thenegative-electrode-side solid electrolyte layer may both contain a solidelectrolyte at the same content (concentration), or may each contain asolid electrolyte at a different content (concentration).

The positive-electrode-side solid electrolyte layer and thenegative-electrode-side solid electrolyte layer may have the samethickness or different thicknesses.

As illustrated in FIG. 1, the entirety of the negative electrode currentcollector may be positioned parallel to the positive electrode currentcollector. Specifically, the distance between the positive electrodecurrent collector and the negative electrode current collector may beconstant over the whole film region. Alternatively, a portion of thenegative electrode current collector may be positioned parallel to thepositive electrode current collector.

Incidentally, as illustrated in FIG. 1, the first electrode layer 100may have a shape (in other words, the first current collector 110 andthe first solid electrolyte layer 130 may have a shape) including acorner portion.

In this case, the corner portion of the first electrode layer 100 mayinclude a first rounded portion 140.

Such a configuration enables a further reduction in the probability ofcoming off of the active material. Specifically, in the corner portionincluding the first rounded portion 140 in the multilayer body includingthe first current collector 110 and the first solid electrolyte layer130, a reduction in concentration of stress (for example, dispersion ofan impact force) is achieved. This enables, in the corner portionincluding the first rounded portion 140, a reduction in the probabilityof separation of the first solid electrolyte layer 130 from the firstcurrent collector 110 (or falling of the solid electrolyte from thefirst current collector 110). Thus, the first solid electrolyte layer130, which is less likely to separate from the first current collector110, is disposed to cover the first active material layer 120. As aresult, for example, even when a corner of the battery beingmanufactured or used collides and impacts, the first solid electrolytelayer 130 enables a reduction in the damage caused on the first activematerial layer 120. In other words, the first solid electrolyte layer130 enables a reduction in the probability of coming off of the activematerial from the first active material layer 120. This prevents shortcircuits within the battery that may be caused by movements of, withinthe battery, the active material coming off from the first activematerial layer 120. This enables further enhanced reliability of thebattery.

In the above-described configuration, the first solid electrolyte layer130, which is less likely to separate from the first current collector110, is disposed to cover the first active material layer 120. In thiscase, even when the first active material layer 120 is disposed toextend close to the corner portion of the first current collector 110,the active material is prevented from coming off from the first activematerial layer 120. Thus, the first active material layer 120 can bedisposed to occupy an area as large as possible, provided that the areais smaller than that of the first current collector 110. This enables afurther increase in the energy density of the battery.

In the present disclosure, the phrase “the shape of a predeterminedlayer” includes the meaning of “the shape of, in the main surfacedirection (x-y plane direction), a predetermined layer”.

FIG. 2 illustrates the schematic configuration of a batteryl100according to Embodiment 1.

FIG. 2(a) is an x-z view (sectional view taken along line 2A-2A)illustrating the schematic configuration of the battery 1100 accordingto Embodiment 1.

FIG. 2(b) is an x-y view (top perspective view) illustrating theschematic configuration of the battery 1100 according to Embodiment 1.

In the battery 1100 according to Embodiment 1, the first rounded portion140 is provided by cutting a corner portion of the first electrode layer100 to form a straight line.

As described above, in the present disclosure, the term “roundedportion” (for example, the first rounded portion 140, a second roundedportion 240, and a rounded portion of an active material layer) includesthe meaning of “a portion provided by cutting to form a curve” (namely,a round portion) as illustrated in FIG. 1, and the meaning of “a portionprovided by cutting to form a straight line” (namely, a portion havingan angle of 90° or larger) as illustrated in FIG. 2.

FIG. 3 illustrates the schematic configuration of a battery 1200according to Embodiment 1.

FIG. 3(a) is an x-z view (sectional view taken along line 3A-3A)illustrating the schematic configuration of the battery 1200 accordingto Embodiment 1.

FIG. 3(b) is an x-y view (top perspective view) illustrating theschematic configuration of the battery 1200 according to Embodiment 1.

The battery 1200 according to Embodiment 1 includes, in addition to theabove-described features of the battery 1000 according to Embodiment 1,the following feature.

Specifically, in the battery 1200 according to Embodiment 1, the firstelectrode layer 100 has a polygon shape including a plurality of cornerportions (for example, a triangular shape, a quadrangular shape or arectangular shape).

In this case, each of the plurality of corner portions of the firstelectrode layer 100 is formed to include the first rounded portion 140.For example, in the example illustrated in FIG. 3, the first electrodelayer 100 having a rectangular shape has four corner portions and all ofthese corner portions are formed to include a first rounded portion 140a, a first rounded portion 140 b, a first rounded portion 140 c, and afirst rounded portion 140 d.

Such a configuration enables a further reduction in the probability ofcoming off of the active material. Specifically, in each corner portionof the multilayer body including the first current collector 110 and thefirst solid electrolyte layer 130, a reduction in concentration ofstress (for example, dispersion of an impact force) is achieved. Thisenables, in each corner portion including the first rounded portion 140,a reduction in the probability of separation of the first solidelectrolyte layer 130 from the first current collector 110 (or fallingof the solid electrolyte from the first current collector 110). Thus,the first solid electrolyte layer 130, which is less likely to separatefrom the first current collector 110, is disposed to cover the firstactive material layer 120. As a result, for example, even when a cornerof the battery being manufactured or used collides and impacts, thefirst solid electrolyte layer 130 enables a reduction in the damagecaused on the first active material layer 120. In other words, the firstsolid electrolyte layer 130 enables a reduction in the probability ofcoming off of the active material from the first active material layer120. This prevents short circuits within the battery that may be causedby movements of, within the battery, the active material coming off fromthe first active material layer 120. This enables further enhancedreliability of the battery.

In the above-described configuration, the first solid electrolyte layer130, which is less likely to separate from the first current collector110, is disposed to cover the first active material layer 120. In thiscase, even when the first active material layer 120 is disposed toextend close to all the corner portions of the first current collector110, the active material is prevented from coming off from the firstactive material layer 120. Thus, the first active material layer 120 canbe disposed to occupy an area as large as possible, provided that thearea is smaller than that of the first current collector 110. Thisenables a further increase in the energy density of the battery.

In the case where a plurality of batteries according to Embodiment 1 arearranged, the above-described configuration in which such firstelectrode layers 100 have a polygon shape enables a denser arrangementof the batteries. Specifically, compared with a configuration employingfirst electrode layers 100 having a circular shape (for example, coinbatteries), the configuration employing first electrode layers 100having a polygon shape (for example, prismatic batteries) enables smallspacing between batteries arranged in a planar direction. This enables afurther increase in the energy density of a battery module (or a batterypack) constituted by arranging a plurality of batteries.

FIG. 4 illustrates the schematic configuration of a batteryl300according to Embodiment 1.

FIG. 4(a) is an x-z view (sectional view taken along line 4A-4A)illustrating the schematic configuration of the battery 1300 accordingto Embodiment 1.

FIG. 4(b) is an x-y view (top perspective view) illustrating theschematic configuration of the battery 1300 according to Embodiment 1.

The battery 1300 according to Embodiment 1 includes, in addition to theabove-described features of the battery 1200 according to Embodiment 1,the following feature.

Specifically, in the battery 1300 according to Embodiment 1, among thecorner portions of the first active material layer 120, corner portionsadjacent to the first rounded portions 140 are formed to include arounded portion. For example, in the example illustrated in FIG. 4,among the corner portions of the first active material layer 120, cornerportions adjacent to the first rounded portion 140 a, the first roundedportion 140 b, the first rounded portion 140 c, and the first roundedportion 140 d are each formed to include a rounded portion.

Such a configuration enables a further reduction in the probability ofcoming off of the active material. Specifically, in the corner portionsof the first active material layer 120, a reduction in concentration ofstress (for example, dispersion of an impact force) is achieved. Thisenables, in each corner portion including the first rounded portion 140,a reduction in the probability of separation of the first activematerial layer 120 from the first current collector 110 (or falling ofthe first active material layer 120 from the first current collector110).

Incidentally, the shape of such a rounded portion of the first activematerial layer 120 may be selected from the above-described shapes forthe first rounded portion 140.

FIGS. 5A to 5E are x-y views (top perspective views) illustrating otherexamples of the shapes of the first current collector 110 and the firstactive material layer 120.

As illustrated in FIG. 5A, among the corner portions of the firstcurrent collector 110, two diagonally opposite corner portions may eachbe formed to include the first rounded portion 140. In this case, thefirst active material layer 120 may have the same shape as the firstcurrent collector 110.

Alternatively, as illustrated in FIG. 5B, among the corner portions ofthe first current collector 110, two adjacent corner portions may eachbe formed to include the first rounded portion 140. In this case, thefirst active material layer 120 may have the same shape as the firstcurrent collector 110.

Alternatively, as illustrated in FIGS. 5C to 5E, among the cornerportions of the first current collector 110, all the corner portions maybe cut to have straight line shapes, to thereby include four firstrounded portions 140. In this case, as illustrated in FIG. 5C, the firstactive material layer 120 may not have any rounded portion.Alternatively, as illustrated in FIG. 5D, the first active materiallayer 120 may have the same shape as the first current collector 110.Alternatively, as illustrated in FIG. 5E, all the corner portions of thefirst active material layer 120 may be cut to have curved shapes, tothereby include four rounded portions.

FIG. 6 illustrates the schematic configuration of a battery 1400according to Embodiment 1.

FIG. 6(a) is an x-z view (sectional view taken along line 6A-6A)illustrating the schematic configuration of the battery 1400 accordingto Embodiment 1.

FIG. 6(b) is an x-y view (top perspective view) illustrating theschematic configuration of the battery 1400 according to Embodiment 1.

The battery 1400 according to Embodiment 1 includes, in addition to theabove-described features of the battery 1000 according to Embodiment 1,the following feature.

Specifically, in the battery 1400 according to Embodiment 1, the secondelectrode layer 200 includes a second current collector 210, a secondactive material layer 220, and a second solid electrolyte layer 230.

The second active material layer 220 is disposed to be in contact withthe second current collector 210, and to occupy a smaller area than thesecond current collector 210.

The second solid electrolyte layer 230 is disposed to be in contact withthe second current collector 210 and the second active material layer220, and to occupy the same area as the second current collector 210.

The second active material layer 220 faces the first active materiallayer 120 with the first solid electrolyte layer 130 and the secondsolid electrolyte layer 230 therebetween.

The first solid electrolyte layer 130 and the second solid electrolytelayer 230 are bonded together.

The peripheral portion of the second electrode layer 200 is formed toinclude a second rounded portion 240.

Such a configuration enables a further reduction in the probability ofcoming off of the active material. Specifically, use of the secondelectrode layer 200, which includes the peripheral portion including thesecond rounded portion 240, enables a reduction in concentration ofstress (for example, dispersion of an impact force) in the peripheralportion including the second rounded portion 240 in the multilayer bodyincluding the second current collector 210 and the second solidelectrolyte layer 230. This enables, in the peripheral portion includingthe second rounded portion 240, a reduction in the probability ofseparation of the second solid electrolyte layer 230 from the secondcurrent collector 210 (or falling of the solid electrolyte from thesecond current collector 210). Thus, the second solid electrolyte layer230, which is less likely to separate from the second current collector210, is disposed to cover the second active material layer 220. As aresult, for example, even when a corner of the battery beingmanufactured or used collides and impacts, the second solid electrolytelayer 230 enables a reduction in the damage caused on the second activematerial layer 220. In other words, the second solid electrolyte layer230 enables a reduction in the probability of coming off of the activematerial from the second active material layer 220. This prevents shortcircuits within the battery that may be caused by movements of, withinthe battery, the active material coming off from the second activematerial layer 220. This enables further enhanced reliability of thebattery.

In the above-described configuration, the second solid electrolyte layer230, which is less likely to separate from the second current collector210, is disposed to cover the second active material layer 220. In thiscase, even when the second active material layer 220 is disposed toextend close to the peripheral portion of the second current collector210, the active material is prevented from coming off from the secondactive material layer 220. Thus, the second active material layer 220can be disposed to occupy an area as large as possible, provided thatthe area is smaller than that of the second current collector 210. Thisenables a further increase in the energy density of the battery.

Incidentally, as illustrated in FIG. 6, the shape of the secondelectrode layer 200 (in other words, the shapes of the second currentcollector 210 and the second solid electrolyte layer 230) may includecorner portions.

In this case, a corner portion of the second electrode layer 200 may beformed to include the second rounded portion 240.

Such a configuration enables a further reduction in the probability ofcoming off of the active material. Specifically, in the corner portionincluding the second rounded portion 240 in the multilayer bodyincluding the second current collector 210 and the second solidelectrolyte layer 230, a reduction in concentration of stress (forexample, dispersion of an impact force) is achieved. This enables, inthe corner portion including the second rounded portion 240, a reductionin the probability of separation of the second solid electrolyte layer230 from the second current collector 210 (or falling of the solidelectrolyte from the second current collector 210). Thus, the secondsolid electrolyte layer 230, which is less likely to separate from thesecond current collector 210, is disposed to cover the second activematerial layer 220. As a result, for example, even when a corner of thebattery being manufactured or used collides and impacts, the secondsolid electrolyte layer 230 enables a reduction in the damage caused onthe second active material layer 220. In other words, the second solidelectrolyte layer 230 enables a reduction in the probability of comingoff of the active material from the second active material layer 220.This prevents short circuits within the battery that may be caused bymovements of, within the battery, the active material coming off fromthe second active material layer 220. This enables further enhancedreliability of the battery.

In the above-described configuration, the second solid electrolyte layer230, which is less likely to separate from the second current collector210, is disposed to cover the second active material layer 220. In thiscase, even when the second active material layer 220 is disposed toextend close to the corner portion of the second current collector 210,the active material is prevented from coming off from the second activematerial layer 220. Thus, the second active material layer 220 can bedisposed to occupy an area as large as possible, provided that the areais smaller than that of the second current collector 210. This enables afurther increase in the energy density of the battery.

Incidentally, the shape of the second rounded portion 240 may beselected from the above-described shapes for the first rounded portion140.

FIG. 7 illustrates the schematic configuration of a battery 1500according to Embodiment 1.

FIG. 7(a) is an x-z view (sectional view taken along line 7A-7A)illustrating the schematic configuration of the battery 1500 accordingto Embodiment 1.

FIG. 7(b) is an x-y view (top perspective view) illustrating theschematic configuration of the battery 1500 according to Embodiment 1.

The battery 1500 according to Embodiment 1 includes, in addition to theabove-described features of the battery 1200 according to Embodiment 1,the following feature.

Specifically, in the battery 1500 according to Embodiment 1, the secondelectrode layer 200 has a polygon shape including a plurality of cornerportions (for example, a triangular shape, a quadrangular shape or arectangular shape).

In this case, all of the corner portions of the second electrode layer200 are formed to include second rounded portions 240. For example, inthe example illustrated in FIG. 7, all of the four corner portions ofthe second electrode layer 200, which has a rectangular shape, areformed to include a second rounded portion 240 a, a second roundedportion 240 b, a second rounded portion 240 c, and a second roundedportion 240 d.

Such a configuration enables a further reduction in the probability ofcoming off of the active material. Specifically, in all the cornerportions of the multilayer body including the second current collector210 and the second solid electrolyte layer 230, a reduction inconcentration of stress (for example, dispersion of an impact force) isachieved. This enables a reduction in the probability of, in all thecorner portions including the second rounded portions 240, separation ofthe second solid electrolyte layer 230 from the second current collector210 (or falling of the solid electrolyte from the second currentcollector 210). Thus, the second solid electrolyte layer 230, which isless likely to separate from the second current collector 210, isdisposed to cover the second active material layer 220. As a result, forexample, even when a corner of the battery being manufactured or usedcollides and impacts, the second solid electrolyte layer 230 enables areduction in the damage caused on the second active material layer 220.In other words, the second solid electrolyte layer 230 enables areduction in the probability of coming off of the active material fromthe second active material layer 220. This prevents short circuitswithin the battery that may be caused by movements of, within thebattery, the active material coming off from the second active materiallayer 220. This enables further enhanced reliability of the battery.

In the above-described configuration, the second solid electrolyte layer230, which is less likely to separate from the second current collector210, is disposed to cover the second active material layer 220. In thiscase, even when the second active material layer 220 is disposed toextend close to all the corner portions of the second current collector210, the active material is prevented from coming off from the secondactive material layer 220. Thus, the second active material layer 220can be disposed to occupy an area as large as possible, provided thatthe area is smaller than that of the second current collector 210. Thisenables a further increase in the energy density of the battery.

In the case where a plurality of batteries according to Embodiment 1 arearranged, the above-described configuration in which such secondelectrode layers 200 have a polygon shape enables a denser arrangementof the batteries. Specifically, compared with a configuration employingsecond electrode layers 200 having a circular shape (for example, coinbatteries), the configuration employing second electrode layers 200having a polygon shape (for example, prismatic batteries) enables smallspacing between batteries arranged in a planar direction. This enables afurther increase in the energy density of a battery module (or a batterypack) constituted by arranging a plurality of batteries.

FIG. 8 illustrates the schematic configuration of a battery 1600according to Embodiment 1.

FIG. 8(a) is an x-z view (sectional view taken along line 8A-8A)illustrating the schematic configuration of the battery 1600 accordingto Embodiment 1.

FIG. 8(b) is an x-y view (top perspective view) illustrating theschematic configuration of the battery 1600 according to Embodiment 1.

The battery 1600 according to Embodiment 1 includes, in addition to theabove-described features of the battery 1500 according to Embodiment 1,the following feature.

Specifically, in the battery 1600 according to Embodiment 1, among thecorner portions of the second active material layer 220, the cornerportions adjacent to the second rounded portions 240 are formed toinclude rounded portions. For example, in the example illustrated inFIG. 8, among the corner portions of the second active material layer220, corner portions adjacent to the second rounded portion 240 a, thesecond rounded portion 240 b, the second rounded portion 240 c, and thesecond rounded portion 240 d are formed to include rounded portions.

Such a configuration enables a further reduction in the probability ofcoming off of the active material. Specifically, in the corner portionsof the second active material layer 220, a reduction in concentration ofstress (for example, dispersion of an impact force) is achieved. Thisenables, in the corner portions including the second rounded portions240, a reduction in the probability of separation of the second activematerial layer 220 from the second current collector 210 (or falling ofthe second active material layer 220 from the second current collector210).

Incidentally, in the battery 1600 according to Embodiment 1, among thecorner portions of the first active material layer 120, corner portionsadjacent to the first rounded portions 140 may be formed to includerounded portions. For example, in the example illustrated in FIG. 8,among the corner portions of the first active material layer 120, cornerportions adjacent to the first rounded portion 140 a, the first roundedportion 140 b, the first rounded portion 140 c, and the first roundedportion 140 d are formed to include rounded portions.

Incidentally, the shape of the rounded portions of the second activematerial layer 220 may be selected from the above-described shapes forthe first rounded portion 140.

Other examples of he shapes of the second current collector 210 and thesecond active material layer 220 include the shapes illustrated in FIGS.5A to 5E as other examples of the shapes of the first current collector110 and the first active material layer 120.

FIG. 9 illustrates the schematic configuration of a batteryl700according to Embodiment 1.

FIG. 9(a) is an x-z view (sectional view taken along line 9A-9A)illustrating the schematic configuration of the battery 1700 accordingto Embodiment 1.

FIG. 9(b) is an x-y view (top perspective view) illustrating theschematic configuration of the battery 1700 according to Embodiment 1.

The battery 1700 according to Embodiment 1 includes, in addition to theabove-described features of the battery 1600 according to Embodiment 1,the following feature.

Specifically, in the battery 1700 according to Embodiment 1, the firstelectrode layer 100 has a circular shape (for example, an ellipticshape, a perfect circle shape, or a coin shape). In this case, the firstrounded portion 140 refers to the edge portion (peripheral portion) ofthe circular first electrode layer 100.

Such a configuration enables a further reduction in the probability ofcoming off of the active material. Specifically, use of the circularfirst electrode layer 100 enables, over the whole peripheral portion ofthe multilayer body including the first current collector 110 and thefirst solid electrolyte layer 130, a reduction in concentration ofstress (for example, dispersion of an impact force). This enables, overthe whole peripheral portion, a reduction in the probability ofseparation of the first solid electrolyte layer 130 from the firstcurrent collector 110 (or falling of the solid electrolyte from thefirst current collector 110). Thus, the first solid electrolyte layer130, which is less likely to separate from the first current collector110, is disposed to cover the first active material layer 120. As aresult, for example, even when a corner of the battery beingmanufactured or used collides and impacts, the first solid electrolytelayer 130 enables a reduction in the damage caused on the first activematerial layer 120. In other words, the first solid electrolyte layer130 enables a reduction in the probability of coming off of the activematerial from the first active material layer 120. This prevents shortcircuits within the battery that may be caused by movements of, withinthe battery, the active material coming off from the first activematerial layer 120. This enables further enhanced reliability of thebattery.

In the above-described configuration, the first solid electrolyte layer130, which is less likely to separate from the first current collector110, is disposed to cover the first active material layer 120. In thiscase, even when the first active material layer 120 is disposed toextend close to the whole peripheral portion of the first currentcollector 110, the active material is prevented from coming off from thefirst active material layer 120. Thus, the first active material layer120 can be disposed to occupy an area as large as possible, providedthat the area is smaller than that of the first current collector 110.This enables a further increase in the energy density of the battery.

Incidentally, in the battery 1700 according to Embodiment 1, the secondelectrode layer 200 may have a circular shape (for example, an ellipticshape, a perfect circle shape, or a coin shape). In this case, thesecond rounded portion 240 refers to the edge portion (peripheralportion) of the circular second electrode layer 200.

Such a configuration enables a further reduction in the probability ofcoming off of the active material. Specifically, use of the circularsecond electrode layer 200 enables, over the whole peripheral portion ofthe multilayer body including the second current collector 210 and thesecond solid electrolyte layer 230, a reduction in concentration ofstress (for example, dispersion of an impact force). This enables, overthe whole peripheral portion, a reduction in the probability ofseparation of the second solid electrolyte layer 230 from the secondcurrent collector 210 (or falling of the solid electrolyte from thesecond current collector 210). Thus, the second solid electrolyte layer230, which is less likely to separate from the second current collector210, is disposed to cover the second active material layer 220. As aresult, for example, even when a corner of the battery beingmanufactured or used collides and impacts, the second solid electrolytelayer 230 enables a reduction in the damage caused on the second activematerial layer 220. In other words, the second solid electrolyte layer230 enables a reduction in the probability of coming off of the activematerial from the second active material layer 220. This prevents shortcircuits within the battery that may be caused by movements of, withinthe battery, the active material coming off from the second activematerial layer 220. This enables further enhanced reliability of thebattery.

In the above-described configuration, the second solid electrolyte layer230, which is less likely to separate from the second current collector210, is disposed to cover the second active material layer 220. In thiscase, even when the second active material layer 220 is disposed toextend close to the whole peripheral portion of the second currentcollector 210, the active material is prevented from coming off from thesecond active material layer 220. Thus, the second active material layer220 can be disposed to occupy an area as large as possible, providedthat the area is smaller than that of the second current collector 210.This enables a further increase in the energy density of the battery.

Incidentally, as illustrated in FIG. 9, in the battery 1700 according toEmbodiment 1, one or both of the first active material layer 120 and thesecond active material layer 220 may have a circular shape (for example,an elliptic shape, a perfect circle shape, or a coin shape).

Such a configuration enables a further reduction in the probability ofcoming off of the active material. Specifically, over the wholeperipheral portion of the first active material layer 120 and the secondactive material layer 220, a reduction in concentration of stress (forexample, dispersion of an impact force) is achieved. This enables, overthe whole peripheral portion, a reduction in the probability ofseparation of the first active material layer 120 from the first currentcollector 110 (or falling of the first active material layer 120 fromthe first current collector 110), and a reduction in the probability ofseparation of the second active material layer 220 from the secondcurrent collector 210 (or falling of the second active material layer220 from the second current collector 210).

Incidentally, in Embodiment 1, the first active material layer 120 maybe disposed to occupy a larger area than the second active materiallayer 220.

In this case, the second active material layer 220 may be disposedwithin the area of the first active material layer 120.

Such a configuration enables suppression of precipitation of metal (forexample, lithium) on the first electrode layer 100. This prevents shortcircuits between the first electrode layer 100 and the second electrodelayer 200 due to precipitation of metal. For example, in the case of alithium ion battery employing a carbonaceous material or metal lithiumfor the negative electrode, the negative-electrode-side potential duringcharge decreases to around a potential at which lithium ions precipitateas metal. Thus, for example, when the battery is charged or rapidlycharged in a low-temperature environment, the negative electrode activematerial may not exhibit a sufficiently high occlusion rate for lithiumions. In this case, lithium ions may precipitate as metal lithium. Thisprecipitation of metal lithium particularly tends to occur at an edgeportion, where current concentrates. Thus, the battery is constitutedsuch that, in a perspective view of the battery viewed on a main surfaceside of the battery, the main surface of the first active material layer120 has a shape contained within the main surface of the second activematerial layer 220. This enables suppression of precipitation of metallithium when the first active material layer 120 is a negative electrodeactive material layer.

Embodiment 2

Hereinafter, Embodiment 2 will be described. Some descriptionsoverlapping those described in Embodiment 1 above will be appropriatelyomitted.

FIG. 10 illustrates the schematic configuration of a battery 2000according to Embodiment 2.

FIG. 10(a) is an x-z view (sectional view taken along line 10A-10A)illustrating the schematic configuration of the battery 2000 accordingto Embodiment 2.

FIG. 10(b) is an x-y view (top perspective view) illustrating theschematic configuration of the battery 2000 according to Embodiment 2.

The battery 2000 according to Embodiment 2 includes, in addition to theabove-described features of the battery 1400 according to Embodiment 1,the following feature.

Specifically, in the battery 2000 according to Embodiment 2, the firstrounded portion 140 and the second rounded portion 240 have the sameshape.

In this case, the first electrode layer 100 and the second electrodelayer 200 are disposed on each other, and the edge portion of the firstrounded portion 140 and the edge portion of the second rounded portion240 are located to coincide with each other.

Such a configuration enables stronger bonding between the first solidelectrolyte layer 130 and the second solid electrolyte layer 230.Specifically, the first electrode layer 100 and the second electrodelayer 200 are disposed on each other, and the edge portion of the firstrounded portion 140 and the edge portion of the second rounded portion240 are located to coincide with each other. In this case, no steppedstructure is formed in the position of the edge portion of the firstrounded portion 140 and the edge portion of the second rounded portion240. This enables, in the position of the edge portion of the firstrounded portion 140 and the edge portion of the second rounded portion240, a reduction in the probability of separation of the second solidelectrolyte layer 230 from the first solid electrolyte layer 130. Thisenables further suppression of coming off of a battery member (forexample, coming off of the active material) due to separation of thesecond solid electrolyte layer 230 from the first solid electrolytelayer 130.

Incidentally, in the present disclosure, the phrase “the shape of therounded portion” includes the meaning of “the shape, in the main surfacedirection (x-y plane direction), of a predetermined layer including therounded portion”.

In the present disclosure, the phrase “two rounded portions have thesame shape” includes the meaning of “two predetermined layers includingtwo rounded portions have the same shape in the main surface direction(x-y plane direction)”.

Incidentally, in the present disclosure, as illustrated in FIG. 10, thephrase “the edge portion of the first rounded portion 140 and the edgeportion of the second rounded portion 240 are located to coincide witheach other” includes the meaning of, for example, “the curved cutportion forming the first rounded portion 140 and the curved cut portionforming the second rounded portion 240 are disposed to overlap such thatno stepped structure is formed”.

In the present disclosure, the phrase “the edge portion of the firstrounded portion 140 and the edge portion of the second rounded portion240 are located to coincide with each other” also includes the meaningof, for example, “the straight cut portion and the 90° or larger cornerportion that form the first rounded portion 140 and the straight cutportion and the 90° or larger corner portion that form the secondrounded portion 240 are disposed to overlap such that no steppedstructure is formed”.

In the present disclosure, the phrase “two predetermined edge portionsare located to coincide with each other” includes the meaning of, forexample, “two predetermined edge portions are located to coincide witheach other except for unavoidable ‘deviation’ due to manufacture error”.In this case, the phrase “two predetermined edge portions are disposedto overlap such that no stepped structure is formed” includes themeaning of “two predetermined edge portions are disposed to overlap suchthat no stepped structure is formed except for stepped structures causedby unavoidable ‘deviation’ due to manufacture error”.

FIG. 11 illustrates the schematic configuration of a battery 2100according to Embodiment 2.

FIG. 11(a) is an x-z view (sectional view taken along line 11A-11A)illustrating the schematic configuration of the battery 2100 accordingto Embodiment 2.

FIG. 11(b) is an x-y view (top perspective view) illustrating theschematic configuration of the battery 2100 according to Embodiment 2.

The battery 2100 according to Embodiment 2 includes, in addition to theabove-described features of the battery 2000 according to Embodiment 2,the following feature.

Specifically, in the battery 2100 according to Embodiment 2, the firstelectrode layer 100 and the second electrode layer 200 have the sameshape.

In this case, the first electrode layer 100 and the second electrodelayer 200 are disposed on each other, and the edge portion of the firstelectrode layer 100 and the edge portion of the second electrode layer200 are located to coincide with each other.

Such a configuration enables stronger bonding between the first solidelectrolyte layer 130 and the second solid electrolyte layer 230.Specifically, the first electrode layer 100 and the second electrodelayer 200 are disposed on each other, and the edge portion of the firstelectrode layer 100 and the edge portion of the second electrode layer200 are located to coincide with each other. In this case, no steppedstructure is formed in the position of the edge portion of the firstelectrode layer 100 and the edge portion of the second electrode layer200. This enables, in the position of the edge portion of the firstelectrode layer 100 and the edge portion of the second electrode layer200, a reduction in the probability of separation of the second solidelectrolyte layer 230 from the first solid electrolyte layer 130. Thisenables further suppression of coming off of a battery member (forexample, coming off of the active material) due to separation of thesecond solid electrolyte layer 230 from the first solid electrolytelayer 130.

Incidentally, in the present disclosure, as illustrated in FIG. 11, thephrase “the edge portion of the first electrode layer 100 and the edgeportion of the second electrode layer 200 are located to coincide witheach other” includes the meaning of, for example, “the straight edgeportions, the corner portions, and the rounded portion of the firstelectrode layer 100, and the straight edge portions, the cornerportions, and the rounded portion of the second electrode layer 200 aredisposed to overlap such that no stepped structure is formed”.

FIG. 12 illustrates the schematic configuration of a battery 2200according to Embodiment 2.

FIG. 12(a) is an x-z view (sectional view taken along line 12A-12A)illustrating the schematic configuration of the battery 2200 accordingto Embodiment 2.

FIG. 12(b) is an x-y view (top perspective view) illustrating theschematic configuration of the battery 2200 according to Embodiment 2.

The battery 2200 according to Embodiment 2 includes, in addition to theabove-described features of the battery 2100 according to Embodiment 2,the following feature.

Specifically, in the battery 2200 according to Embodiment 2, all thecorner portions of the first electrode layer 100 are formed to includethe first rounded portions 140 (140 a, 140 b, 140 c, and 140 d).

In addition, all the corner portions of the second electrode layer 200are formed to include the second rounded portions 240 (240 a, 240 b, 240c, and 240 d).

Incidentally, in the present disclosure, as illustrated in FIG. 12, thephrase “the edge portion of the first electrode layer 100 and the edgeportion of the second electrode layer 200 are located to coincide witheach other” includes the meaning of, for example, “the straight edgeportions and all the rounded portions of the first electrode layer 100and the straight edge portions and all the rounded portions of thesecond electrode layer 200 are disposed to overlap such that no steppedstructure is formed”.

FIG. 13 illustrates the schematic configuration of a battery 2300according to Embodiment 2.

FIG. 13(a) is an x-z view (sectional view taken along line 13A-13A)illustrating the schematic configuration of the battery 2300 accordingto Embodiment 2.

FIG. 13(b) is an x-y view (top perspective view) illustrating theschematic configuration of the battery 2300 according to Embodiment 2.

The battery 2300 according to Embodiment 2 includes, in addition to theabove-described features of the battery 2000 according to Embodiment 2,the following feature.

Specifically, in the battery 2300 according to Embodiment 2, the firstelectrode layer 100 has a circular shape (for example, an ellipticshape, a perfect circle shape, or a coin shape).

The second electrode layer 200 has a circular shape (for example, anelliptic shape, a perfect circle shape, or a coin shape).

Incidentally, in the present disclosure, as illustrated in FIG. 13, thephrase “the edge portion of the first electrode layer 100 and the edgeportion of the second electrode layer 200 are located to coincide witheach other” includes the meaning of, for example, “the curved edgeportion (peripheral portion) forming the first rounded portion 140 ofthe first electrode layer 100 and the curved edge portion (peripheralportion) forming the second rounded portion 240 of the second electrodelayer 200 are disposed to overlap such that no stepped structure isformed”.

Incidentally, as illustrated in FIG. 13, in the battery 2300 accordingto Embodiment 2, one or both of the first active material layer 120 andthe second active material layer 220 may have a circular shape (forexample, an elliptic shape, a perfect circle shape, or a coin shape).

Such a configuration enables a further reduction in the probability ofcoming off of the active material. Specifically, over the wholeperipheral portion of the first active material layer 120 and the secondactive material layer 220, a reduction in concentration of stress (forexample, dispersion of an impact force) is achieved. This enables, overthe whole peripheral portion, a reduction in the probability ofseparation of the first active material layer 120 from the first currentcollector 110 (or falling of the first active material layer 120 fromthe first current collector 110), and a reduction in the probability ofseparation of the second active material layer 220 from the secondcurrent collector 210 (or falling of the second active material layer220 from the second current collector 210).

Embodiment 3

Hereinafter, Embodiment 3 will be described. Some descriptionsoverlapping those described in Embodiment 1 or 2 above will beappropriately omitted.

FIG. 14 illustrates the schematic configuration of a battery 000according to Embodiment 3.

FIG. 14(a) is an x-z view (sectional view taken along line 14A-14A)illustrating the schematic configuration of the battery 3000 accordingto Embodiment 3.

FIG. 14(b) is an x-y view (top perspective view) illustrating theschematic configuration of the battery 3000 according to Embodiment 3.

The battery 3000 according to Embodiment 3 includes, in addition to theabove-described features of the battery 1000 according to Embodiment 1,the following feature.

Specifically, in the battery 3000 according to Embodiment 3, the secondelectrode layer 200 includes a second current collector 210 and a secondactive material layer 220.

The second active material layer 220 is disposed to be in contact withthe second current collector 210, and to occupy a smaller area than thesecond current collector 210.

The first solid electrolyte layer 130 is disposed to be in contact withthe second current collector 210 and the second active material layer220, and to occupy the same area as the second current collector 210.

The second active material layer 220 faces the first active materiallayer 120 with the first solid electrolyte layer 130 therebetween.

The peripheral portion of the second current collector 210 is formed toinclude the second rounded portion 240.

The first rounded portion 140 and the second rounded portion 240 havethe same shape.

The first electrode layer 100 and the second electrode layer 200 aredisposed on each other, and the edge portion of the first roundedportion 140 and the edge portion of the second rounded portion 240 arelocated to coincide with each other.

Such a configuration enables stronger bonding between the first solidelectrolyte layer 130 and the second current collector 210.Specifically, the first electrode layer 100 and the second electrodelayer 200 are disposed on each other, and the edge portion of the firstrounded portion 140 and the edge portion of the second rounded portion240 are located to coincide with each other. In this case, no steppedstructure is formed in the position of the edge portion of the firstrounded portion 140 and the edge portion of the second rounded portion240. This enables, in the position of the edge portion of the firstrounded portion 140 and the edge portion of the second rounded portion240, a reduction in the probability of separation of the second currentcollector 210 from the first solid electrolyte layer 130. This enablesfurther suppression of coming off of a battery member (for example,coming off of the active material) due to separation of the secondcurrent collector 210 from the first solid electrolyte layer 130.

FIG. 15 illustrates the schematic configuration of a battery 3100according to Embodiment 3.

FIG. 15(a) is an x-z view (sectional view taken along line 15A-15A)illustrating the schematic configuration of the battery 3100 accordingto Embodiment 3.

FIG. 15(b) is an x-y view (top perspective view) illustrating theschematic configuration of the battery 3100 according to Embodiment 3.

The battery 3100 according to Embodiment 3 includes, in addition to theabove-described features of the battery 3000 according to Embodiment 3,the following feature.

Specifically, in the battery 3100 according to Embodiment 3, the firstelectrode layer 100 and the second electrode layer 200 have the sameshape.

The first electrode layer 100 and the second electrode layer 200 aredisposed on each other, and the edge portion of the first electrodelayer 100 and the edge portion of the second electrode layer 200 arelocated to coincide with each other.

Such a configuration enables stronger bonding between the first solidelectrolyte layer 130 and the second current collector 210.Specifically, the first electrode layer 100 and the second electrodelayer 200 are disposed on each other, and the edge portion of the firstelectrode layer 100 and the edge portion of the second electrode layer200 are located to coincide with each other. In this case, no steppedstructure is formed in the position of the edge portion of the firstelectrode layer 100 and the edge portion of the second electrode layer200. This enables, in the position of the edge portion of the firstelectrode layer 100 and the edge portion of the second electrode layer200, a reduction in the probability of separation of the second currentcollector 210 from the first solid electrolyte layer 130. This enablesfurther suppression of coming off of a battery member (for example,coming off of the active material) due to separation of the secondcurrent collector 210 from the first solid electrolyte layer 130.

FIG. 16 illustrates the schematic configuration of a battery 3200according to Embodiment 3.

FIG. 16(a) is an x-z view (sectional view taken along line 16A-16A)illustrating the schematic configuration of the battery 3200 accordingto Embodiment 3.

FIG. 16(b) is an x-y view (top perspective view) illustrating theschematic configuration of the battery 3200 according to Embodiment 3.

The battery 3200 according to Embodiment 3 includes, in addition to theabove-described features of the battery 3100 according to Embodiment 3,the following feature.

Specifically, in the battery 3200 according to Embodiment 3, the firstelectrode layer 100 and the second electrode layer 200 have a circularshape.

Such a configuration enables stronger bonding between the first solidelectrolyte layer 130 and the second current collector 210.Specifically, the first electrode layer 100 and the second electrodelayer 200 are disposed on each other, and the edge portion of thecircular first electrode layer 100 and the edge portion of the circularsecond electrode layer 200 are located to coincide with each other. Inthis case, in the position over the whole peripheral portion of thefirst electrode layer 100 and the second electrode layer 200, no steppedstructure is formed. This enables, in the position over the wholeperipheral portion of the first electrode layer 100 and the secondelectrode layer 200, a reduction in the probability of separation of thesecond current collector 210 from the first solid electrolyte layer 130.This enables further suppression of coming off of a battery member (forexample, coming off of the active material) due to separation of thesecond current collector 210 from the first solid electrolyte layer 130.

Incidentally, as illustrated in FIG. 16, in the battery 3200 accordingto Embodiment 3, one or both of the first active material layer 120 andthe second active material layer 220 may have a circular shape (forexample, an elliptic shape, a perfect circle shape, or a coin shape).

Such a configuration enables a further reduction in the probability ofcoming off of the active material. Specifically, over the wholeperipheral portion of the first active material layer 120 and the secondactive material layer 220, a reduction in concentration of stress (forexample, dispersion of an impact force) is achieved. This enables, overthe whole peripheral portion, a reduction in the probability ofseparation of the first active material layer 120 from the first currentcollector 110 (or falling of the first active material layer 120 fromthe first current collector 110), and a reduction in the probability ofseparation of the second active material layer 220 from the secondcurrent collector 210 (or falling of the second active material layer220 from the second current collector 210).

Embodiment 4

Hereinafter, Embodiment 4 will be described. Some descriptionsoverlapping any of those described in Embodiments 1 to 3 above will beappropriately omitted.

FIG. 17 illustrates the schematic configuration of a battery 4000according to Embodiment 4.

FIG. 17(a) is an x-z view (sectional view taken along line 17A-17A)illustrating the schematic configuration of the battery 4000 accordingto Embodiment 4.

FIG. 17(b) is an x-y view (top perspective view) illustrating theschematic configuration of the battery 4000 according to Embodiment 4.

The battery 4000 according to Embodiment 4 includes, in addition to theabove-described features of the battery 1000 according to Embodiment 1,the following feature.

Specifically, the battery 4000 according to Embodiment 4 furtherincludes a third electrode layer 300.

The third electrode layer 300 is disposed on the first electrode layer100. The third electrode layer 300 serves as the counter electrode forthe first electrode layer 100.

The third electrode layer 300 includes a third current collector 310, athird active material layer 320, and a third solid electrolyte layer330.

The first current collector 110 and the third current collector 310 areelectrically connected to each other.

The third active material layer 320 is disposed to be in contact withthe third current collector 310, and to occupy a smaller area than thethird current collector 310.

The third solid electrolyte layer 330 is disposed to be in contact withthe third current collector 310 and the third active material layer 320,and to occupy the same area as the third current collector 310.

The peripheral portion of the third electrode layer 300 is formed toinclude a third rounded portion 340.

The first rounded portion 140 and the third rounded portion 340 have thesame shape.

The first electrode layer 100 and the third electrode layer 300 aredisposed on each other, and the edge portion of the first roundedportion 140 and the edge portion of the third rounded portion 340 arelocated to coincide with each other.

Such a configuration enables a further reduction in the probability ofcoming off of the active material. Specifically, use of the thirdelectrode layer 300 including a peripheral portion including the thirdrounded portion 340 enables a reduction in concentration of stress (forexample, dispersion of an impact force) in the peripheral portionincluding the third rounded portion 340 in the multilayer body includingthe third current collector 310 and the third solid electrolyte layer330. This enables, in the peripheral portion including the third roundedportion 340, a reduction in the probability of separation of the thirdsolid electrolyte layer 330 from the third current collector 310 (orfalling of the solid electrolyte from the third current collector 310).Thus, the third solid electrolyte layer 330, which is less likely toseparate from the third current collector 310, is disposed to cover thethird active material layer 320. As a result, for example, even when acorner of the battery being manufactured or used collides and impacts,the third solid electrolyte layer 330 enables a reduction in the damagecaused on the third active material layer 320. In other words, the thirdsolid electrolyte layer 330 enables a reduction in the probability ofcoming off of the active material from the third active material layer320. This prevents short circuits within the battery that may be causedby movements of, within the battery, the active material coming off fromthe third active material layer 320. This enables further enhancedreliability of the battery.

In the above-described configuration, the third solid electrolyte layer330, which is less likely to separate from the third current collector310, is disposed to cover the third active material layer 320. In thiscase, even when the third active material layer 320 is disposed toextend close to the peripheral portion of the third current collector310, the active material is prevented from coming off from the thirdactive material layer 320. Thus, the third active material layer 320 canbe disposed to occupy an area as large as possible, provided that thearea is smaller than that of the third current collector 310. Thisenables a further increase in the energy density of the battery.

The above-described configuration enables stronger bonding between thefirst electrode layer 100 and the third electrode layer 300.Specifically, the first electrode layer 100 and the third electrodelayer 300 are disposed on each other, and the edge portion of the firstrounded portion 140 and the edge portion of the third rounded portion340 are located to coincide with each other. In this case, no steppedstructure is formed in the position of the edge portion of the firstrounded portion 140 and the edge portion of the third rounded portion340. This enables, in the position of the edge portion of the firstrounded portion 140 and the edge portion of the third rounded portion340, a reduction in the probability of separation of the third electrodelayer 300 (for example, the third current collector 310) from the firstelectrode layer 100 (for example, the first current collector 110). Thisenables further suppression of coming off of a battery member (forexample, coming off of the active material) due to separation of thethird electrode layer 300 from the first electrode layer 100, and alsoenables suppression of, for example, concentration of current and anincrease in the resistance due to partial separation of the thirdelectrode layer 300 from the first electrode layer 100.

The third active material layer 320 contains a counter electrodematerial (for example, an active material).

The third solid electrolyte layer 330 is a solid electrolyte layercontaining a solid electrolyte.

Incidentally, the first active material layer 120 may be a negativeelectrode active material layer. In this case, the electrode material isa negative electrode active material. The first current collector 110 isa negative electrode current collector. The first solid electrolytelayer 130 is a negative-electrode-side solid electrolyte layer. Thethird active material layer 320 is a positive electrode active materiallayer. The counter electrode material is a positive electrode activematerial. The third current collector 310 is a positive electrodecurrent collector. The third solid electrolyte layer 330 is apositive-electrode-side solid electrolyte layer.

Alternatively, the first active material layer 120 may be a positiveelectrode active material layer. In this case, the electrode material isa positive electrode active material. The first current collector 110 isa positive electrode current collector. The first solid electrolytelayer 130 is a positive-electrode-side solid electrolyte layer. Thethird active material layer 320 is a negative electrode active materiallayer. The counter electrode material is a negative electrode activematerial. The third current collector 310 is a negative electrodecurrent collector. The third solid electrolyte layer 330 is anegative-electrode-side solid electrolyte layer.

Incidentally, as illustrated in FIG. 17, the third active material layer320 and the third solid electrolyte layer 330 may be disposed on, of themain surfaces of the third current collector 310, a main surface side onwhich the first current collector 110 is not disposed.

As illustrated in FIG. 17, the third current collector 310 may bedisposed on, of the main surfaces of the first current collector 110, amain surface side on which the first active material layer 120 is notdisposed.

As illustrated in FIG. 17, a main surface of the first current collector110 and a main surface of the third current collector 310 may bedisposed in direct contact with each other. Alternatively, anothermember that is electrically conductive (for example, an adhesive layercontaining an adhesive material) may be disposed between a main surfaceof the first current collector 110 and a main surface of the thirdcurrent collector 310.

Incidentally, as illustrated in FIG. 17, the first electrode layer 100and the third electrode layer 300 may have the same shape.

In this case, the first electrode layer 100 and the third electrodelayer 300 are disposed on each other, and the edge portion of the firstelectrode layer 100 and the edge portion of the third electrode layer300 may be located to coincide with each other.

Such a configuration enables stronger bonding between the firstelectrode layer 100 and the third electrode layer 300. Specifically, thefirst electrode layer 100 and the third electrode layer 300 are disposedon each other, and the edge portion of the first electrode layer 100 andthe edge portion of the third electrode layer 300 are located tocoincide with each other. In this case, no stepped structure is formedin the position of the edge portion of the first electrode layer 100 andthe edge portion of the third electrode layer 300. This enables, in theposition of the edge portion of the first electrode layer 100 and theedge portion of the third electrode layer 300, a reduction in theprobability of separation of the third electrode layer 300 (for example,the third current collector 310) from the first electrode layer 100 (forexample, the first current collector 110). This enables furthersuppression of coming off of a battery member (for example, coming offof the active material) due to separation of the third electrode layer300 from the first electrode layer 100, and also enables furthersuppression of, for example, concentration of current and an increase inthe resistance due to partial separation of the third electrode layer300 from the first electrode layer 100.

Incidentally, the shape of the third rounded portion 340 may be selectedfrom the above-described shapes for the first rounded portion 140.

The shape of the third electrode layer 300 may be selected from theabove-described shapes for the first electrode layer 100.

Other examples of the shapes of the third current collector 310 and thethird active material layer 320 include the shapes illustrated in FIGS.5A to 5E as other examples of the shapes of the first current collector110 and the first active material layer 120.

FIG. 18 is an x-z view (sectional view) illustrating the schematicconfiguration of a battery 4100 according to Embodiment 4.

The battery 4100 according to Embodiment 4 includes, in addition to theabove-described features of the battery 4000 according to Embodiment 4,the following feature.

Specifically, the battery 4100 according to Embodiment 4 furtherincludes a second electrode layer 200 and a fourth electrode layer 400.

The fourth electrode layer 400 is of a polarity the same as that of thefirst electrode layer 100. The fourth electrode layer 400 includes afourth current collector 410 and a fourth active material layer 420. Thefourth active material layer 420 contains an electrode material (forexample, an active material).

Such a configuration enables a stack battery in which the probability ofcoming off of the active materials is reduced. More specifically, theconfiguration enables a stack battery in which a first power generationelement (a power generation element constituted by the first electrodelayer 100 and the second electrode layer 200) and a second powergeneration element (a power generation element constituted by the thirdelectrode layer 300 and the fourth electrode layer 400) are connectedtogether in series. This enables a reduction in the probability ofcoming off of active materials, and also enables a high battery voltagedue to the serial connection of a plurality of power generationelements.

FIG. 19 is an x-z view (sectional view) illustrating the schematicconfiguration of a battery 4200 according to Embodiment 4.

The battery 4200 according to Embodiment 4 includes, in addition to theabove-described features of the battery 4100 according to Embodiment 4,the following feature.

Specifically, in the battery 4200 according to Embodiment 4, the secondelectrode layer 200 includes a second solid electrolyte layer 230. Inthis case, the first solid electrolyte layer 130 and the second solidelectrolyte layer 230 are bonded together.

The fourth electrode layer 400 includes a fourth solid electrolyte layer430. The fourth solid electrolyte layer 430 is a solid electrolyte layercontaining a solid electrolyte.

In this case, the third solid electrolyte layer 330 and the fourth solidelectrolyte layer 430 are bonded together.

Such a configuration enables a reduction in the probability of shortcircuits due to pinholes that may be generated in the solid electrolytelayers. This enables a reduction in the probability of coming off ofactive materials and a reduction in the probability of short circuits,and also enables a high battery voltage due to the serial connection ofa plurality of power generation elements.

Incidentally, the first electrode layer 100, the second electrode layer200, the third electrode layer 300, and the fourth electrode layer 400may have the same shape.

Such a configuration enables a further reduction in the probability ofcoming off of active materials from the electrode layers, and a furtherreduction in the probability of separation between the electrode layers.

Embodiment 5

Hereinafter, Embodiment 5 will be described. Some descriptionsoverlapping any of those described in Embodiments 1 to 4 above will beappropriately omitted.

FIG. 20 illustrates the schematic configuration of a battery 5000according to Embodiment 5.

FIG. 20(a) is an x-z view (sectional view taken along line 20A-20A)illustrating the schematic configuration of the battery 5000 accordingto Embodiment 5.

FIG. 20(b) is an x-y view (top perspective view) illustrating theschematic configuration of the battery 5000 according to Embodiment 5.

The battery 5000 according to Embodiment 5 includes, in addition to theabove-described features of the battery 1000 according to Embodiment 1,the following feature.

Specifically, the battery 5000 according to Embodiment 5 furtherincludes a third electrode layer 300.

The third electrode layer 300 is disposed on the first electrode layer100. The third electrode layer 300 serves as the counter electrode forthe first electrode layer 100.

The third electrode layer 300 includes a third active material layer 320and a third solid electrolyte layer 330.

The third active material layer 320 is disposed to be in contact withthe first current collector 110, and to occupy a smaller area than thefirst current collector 110.

The third solid electrolyte layer 330 is disposed to be in contact withthe first current collector 110 and the third active material layer 320,and to occupy the same area as the first current collector 110.

The peripheral portion of the third electrode layer 300 is formed toinclude a third rounded portion 340.

The first rounded portion 140 and the third rounded portion 340 have thesame shape.

The first electrode layer 100 and the third electrode layer 300 aredisposed on each other, and the edge portion of the first roundedportion 140 and the edge portion of the third rounded portion 340 arelocated to coincide with each other.

Such a configuration enables a further reduction in the probability ofcoming off of the active material. Specifically, use of the thirdelectrode layer 300 including the peripheral portion including the thirdrounded portion 340 enables a reduction in concentration of stress (forexample, dispersion of an impact force) in the peripheral portionincluding the third rounded portion 340 in the multilayer body includingthe first current collector 110 and the third solid electrolyte layer330. This enables, in the peripheral portion including the third roundedportion 340, a reduction in the probability of separation of the thirdsolid electrolyte layer 330 from the first current collector 110 (orfalling of the solid electrolyte from the first current collector 110).Thus, the third solid electrolyte layer 330, which is less likely toseparate from the first current collector 110, is disposed to cover thethird active material layer 320. As a result, for example, even when acorner of the battery being manufactured or used collides and impacts,the third solid electrolyte layer 330 enables a reduction in the damagecaused on the third active material layer 320. In other words, the thirdsolid electrolyte layer 330 enables a reduction in the probability ofcoming off of the active material from the third active material layer320. This prevents short circuits within the battery that may be causedby movements of, within the battery, the active material coming off fromthe third active material layer 320. This enables further enhancedreliability of the battery.

In the above-described configuration, the third solid electrolyte layer330, which is less likely to separate from the first current collector110, is disposed to cover the third active material layer 320. In thiscase, even when the third active material layer 320 is disposed toextend close to the peripheral portion of the first current collector110, the active material is prevented from coming off from the thirdactive material layer 320. Thus, the third active material layer 320 canbe disposed to occupy an area as large as possible, provided that thearea is smaller than that of the first current collector 110. Thisenables a further increase in the energy density of the battery.

Incidentally, as illustrated in FIG. 20, the third active material layer320 and the third solid electrolyte layer 330 may be disposed on, of themain surfaces of the first current collector 110, a main surface side onwhich the first active material layer 120 is not disposed. Thus, thefirst current collector 110 serves as a bipolar current collector. Thefirst current collector 110, the first active material layer 120, andthe third active material layer 320 constitute a bipolar electrode.

FIG. 21 is an x-z view (sectional view) illustrating the schematicconfiguration of a battery 5100 according to Embodiment 5.

The battery 5100 according to Embodiment 5 includes, in addition to theabove-described features of the battery 5000 according to Embodiment 5,the following feature.

Specifically, the battery 100 according to Embodiment 5 further includesa second electrode layer 200 and a fourth electrode layer 400.

The fourth electrode layer 400 is of a polarity the same as that of thefirst electrode layer 100. The fourth electrode layer 400 includes afourth current collector 410 and a fourth active material layer 420. Thefourth active material layer 420 contains an electrode material (forexample, an active material).

Such a configuration enables a stack battery in which the probability ofcoming off of the active materials is reduced. More specifically, theconfiguration enables a stack battery in which a first power generationelement (a power generation element constituted by the first electrodelayer 100 and the second electrode layer 200) and a second powergeneration element (a power generation element constituted by the thirdelectrode layer 300 and the fourth electrode layer 400) are connectedtogether in series. This enables a reduction in the probability ofcoming off of active materials, and also enables a high battery voltagedue to the serial connection of a plurality of power generationelements.

The above-described configuration, in which the bipolar electrodeconstituted by the first current collector 110, the first activematerial layer 120, and the third active material layer 320 is used,enables strong bonding between the first power generation element andthe second power generation element, compared with the case of theabove-described configuration of the battery 4100 according toEmbodiment 4 using the multilayer body including the first currentcollector 110 and the third current collector 310.

FIG. 22 is an x-z view (sectional view) illustrating the schematicconfiguration of a battery 5200 according to Embodiment 5.

The battery 5200 according to Embodiment 5 includes, in addition to theabove-described features of the battery 5100 according to Embodiment 5,the following feature.

Specifically, in the battery 5200 according to Embodiment 5, the secondelectrode layer 200 includes a second solid electrolyte layer 230. Inthis case, the first solid electrolyte layer 130 and the second solidelectrolyte layer 230 are bonded together.

The fourth electrode layer 400 includes a fourth solid electrolyte layer430. The fourth solid electrolyte layer 430 is a solid electrolyte layercontaining a solid electrolyte.

In this case, the third solid electrolyte layer 330 and the fourth solidelectrolyte layer 430 are bonded together.

Such a configuration enables a reduction in the probability of shortcircuits due to pinholes that may be generated in the solid electrolytelayers. Thus, the configuration enables a reduction in the probabilityof coming off of active materials and a reduction in the probability ofshort circuits, and also enables a high battery voltage due to theserial connection of a plurality of power generation elements.

Incidentally, the first electrode layer 100, the second electrode layer200, the third electrode layer 300, and the fourth electrode layer 400may have the same shape.

Such a configuration enables a further reduction in the probability ofcoming off of active materials from the electrode layers, and a furtherreduction in the probability of separation between the electrode layers.

Incidentally, the batteries according to Embodiments 1 to 5 may be, forexample, all-solid-state batteries (for example, all-solid-state lithiumsecondary batteries). The batteries according to Embodiments 1 to 5enable all-solid-state batteries in which short circuits between thepositive and negative electrodes are suppressed in the batteries beingmanufactured and charged. Even when a high voltage (for example, avoltage equal to or higher than that of two battery cells) is required,such a stack all-solid-state battery including solid electrolytes iseasily manufactured to generate such a high voltage by directlyconnecting together in series a plurality of power generation elementswithin each battery cell. Each of the batteries according to Embodiments1 to 5 enables, even when a plurality of cells are stacked, a stackall-solid-state battery in which short circuits between the positive andnegative electrodes do not occur.

Incidentally, methods for manufacturing the batteries according toEmbodiments 1 to 5 will be described as Embodiments 6 and 7 below.

Embodiment 6

Hereinafter, Embodiment 6 will be described. Some descriptionsoverlapping any of those described in Embodiments 1 to 5 above will beappropriately omitted.

FIG. 23 illustrates the schematic configuration of a batterymanufacturing apparatus 6000 according to Embodiment 6.

The battery manufacturing apparatus 6000 according to Embodiment 6includes a first-electrode-layer formation unit 610, asecond-electrode-layer formation unit 620, and a layer disposition unit630.

The first-electrode-layer formation unit 610 is configured to form thefirst electrode layer 100.

The first-electrode-layer formation unit 610 is configured to form thefirst active material layer 120 to be in contact with the first currentcollector 110, and to occupy a smaller area than the first currentcollector 110.

The first-electrode-layer formation unit 610 is configured to form thefirst solid electrolyte layer 130 to be in contact with the firstcurrent collector 110 and the first active material layer 120, and tooccupy the same area as the first current collector 110.

The second-electrode-layer formation unit 620 is configured to form thesecond electrode layer 200.

The second-electrode-layer formation unit 620 is configured to form thesecond active material layer 220 to be in contact with the secondcurrent collector 210, and to occupy a smaller area than the secondcurrent collector 210.

The second-electrode-layer formation unit 620 is configured to form thesecond solid electrolyte layer 230 to be in contact with the secondcurrent collector 210 and the second active material layer 220, and tooccupy the same area as the second current collector 210.

The layer disposition unit 630 is configured to dispose the firstelectrode layer 100 and the second electrode layer 200 on each other.Thus, the layer disposition unit 630 is configured to dispose the firstactive material layer 120 to face the second active material layer 220with the first solid electrolyte layer 130 and the second solidelectrolyte layer 230 therebetween.

FIG. 24 is a flowchart illustrating a battery manufacturing methodaccording to Embodiment 6.

The battery manufacturing method according to Embodiment 6 is a batterymanufacturing method using the battery manufacturing apparatus 6000according to Embodiment 6. For example, the battery manufacturing methodaccording to Embodiment 6 is a battery manufacturing method performed inthe battery manufacturing apparatus 6000 according to Embodiment 6.

The battery manufacturing method according to Embodiment 6 includes afirst-active-material-layer formation step S1110 (Step a1), afirst-solid-electrolyte-layer formation step S1120 (Step a2), asecond-active-material-layer formation step S1210 (Step b1), asecond-solid-electrolyte-layer formation step S1220 (Step b2), and alayer disposition step S1310 (Step c).

The first-active-material-layer formation step S1110 is a step offorming, with the first-electrode-layer formation unit 610, the firstactive material layer 120 to be in contact with the first currentcollector 110, and to occupy a smaller area than the first currentcollector 110.

The first-solid-electrolyte-layer formation step S1120 is a step offorming, with the first-electrode-layer formation unit 610, the firstsolid electrolyte layer 130 to be in contact with the first currentcollector 110 and the first active material layer 120, and to occupy thesame area as the first current collector 110. Thefirst-solid-electrolyte-layer formation step S1120 is performed afterthe first-active-material-layer formation step S1110.

The second-active-material-layer formation step S1210 is a step offorming, with the second-electrode-layer formation unit 620, the secondactive material layer 220 to be in contact with the second currentcollector 210, and to occupy a smaller area than the second currentcollector 210.

The second-solid-electrolyte-layer formation step S1220 is a step offorming, with the second-electrode-layer formation unit 620, the secondsolid electrolyte layer 230 to be in contact with the second currentcollector 210 and the second active material layer 220, and to occupythe same area as the second current collector 210. Thesecond-solid-electrolyte-layer formation step S1220 is performed afterthe second-active-material-layer formation step S1210.

The layer disposition step S1310 is a step of disposing, with the layerdisposition unit 630, the first electrode layer 100 and the secondelectrode layer 200 on each other such that the first active materiallayer 120 faces the second active material layer 220 with the firstsolid electrolyte layer 130 and the second solid electrolyte layer 230therebetween. The layer disposition step S1310 is performed after thefirst-solid-electrolyte-layer formation step S1120 and thesecond-solid-electrolyte-layer formation step S1220.

In the above-described manufacturing apparatus or manufacturing method,the first solid electrolyte layer 130 is formed to occupy the same areaas the first current collector 110, the second solid electrolyte layer230 is formed to occupy the same area as the second current collector210, and then the first electrode layer 100 and the second electrodelayer 200 are disposed on each other. This enables, even duringmanufacture of the battery, further enhancement of positional stabilityof the first current collector 110 and the second current collector 210,and a further reduction in the probability of contact between the firstcurrent collector 110 and the second current collector 210.

In addition, the above-described manufacturing apparatus ormanufacturing method enables a further reduction in the probability ofcontact between the first current collector 110 and the second currentcollector 210. Specifically, a portion between the first currentcollector 110 and the second current collector 210, which face eachother with the portion therebetween, is fixed with the first solidelectrolyte layer 130 and the second solid electrolyte layer 230. Forexample, even when the first current collector 110 and the secondcurrent collector 210 are constituted by thin films, the presence of thefirst solid electrolyte layer 130 and the second solid electrolyte layer230 enables the spacing between the first current collector 110 and thesecond current collector 210 to be maintained to have at least apredetermined distance (for example, equal to or longer than the totalthickness of the first solid electrolyte layer 130 and the second solidelectrolyte layer 230). This prevents the first current collector 110and the second current collector 210 from coming into close proximity toeach other. This prevents, for example, even when a plurality of batterycells are stacked, deformation of the first current collector 110 andthe second current collector 210. Thus, for example, even when aplurality of battery cells are stacked, short circuits are preventedbetween the first current collector 110 and the second current collector210. In addition, in another example that is an all-solid-state batterynot having any separator between the first electrode layer 100 and thesecond electrode layer 200, the risk of short circuits caused by directcontact between the first current collector 110 and the second currentcollector 210 is reduced.

In addition, the above-described manufacturing apparatus ormanufacturing method eliminates the necessity of an additional memberfor insulation between the first electrode layer 100 and the secondelectrode layer 200 (for example, an insulation spacer). This enablesfurther simplification of and a reduction in the costs for batterymanufacturing steps.

In addition, the above-described manufacturing apparatus ormanufacturing method provides a solid electrolyte layer in which thefirst solid electrolyte layer 130 and the second solid electrolyte layer230 are bonded together. This enables a reduction in the probability ofshort circuits due to pinholes that may be generated, for example,during manufacture, in the first solid electrolyte layer 130 and thesecond solid electrolyte layer 230.

Incidentally, in the above-described manufacturing method, the firstcurrent collector 110 may be a current collector including a peripheralportion including the first rounded portion 140. In this case, the shapeof the first rounded portion 140 (or the shape of the first currentcollector 110) may be selected from the above-described shapes inEmbodiments 1 to 5. In this case, the first solid electrolyte layer 130is formed to occupy the same area as the first current collector 110, sothat the first rounded portion 140 is formed in the peripheral portionsof the first current collector 110 and the first solid electrolyte layer130. Thus, the first electrode layer 100 including the first roundedportion 140 is formed.

In the above-described manufacturing method, the second currentcollector 210 may be a current collector including a peripheral portionincluding the second rounded portion 240. In this case, the shape of thesecond rounded portion 240 (or the shape of the second current collector210) may be selected from the above-described shapes in Embodiments 1 to5. In this case, the second solid electrolyte layer 230 is formed tooccupy the same area as the second current collector 210, so that thesecond rounded portion 240 is formed in the peripheral portions of thesecond current collector 210 and the second solid electrolyte layer 230.Thus, the second electrode layer 200 including the second roundedportion 240 is formed.

The third electrode layer 300 including the third rounded portion 340,and the fourth electrode layer 400 including the fourth rounded portion440 can also be formed by the same method as above.

The size of the main surfaces of current collectors prepared may bechanged, which results in a change in the size of the main surfaces ofthe electrode layers. In this case, the electrode layers can be formedto have rounded portions that have the same shape, or the electrodelayers can be formed to have the same shape.

In the layer disposition step, the positions of the electrode layersbeing disposed may be adjusted. This enables disposition of theelectrode layers in which the edge portions of the rounded portions ofthe electrode layers are located to coincide with each other, or enablesdisposition of the electrode layers in which the edge portions of theelectrode layers are located to coincide with each other.

In each of the active-material-layer formation steps, the area where theactive material layer is formed may be adjusted. This enables formationof a rounded portion in the edge portion of the active material layer.

Incidentally, in the battery manufacturing apparatus 6000 according toEmbodiment 6, the second-electrode-layer formation unit 620 may beconfigured to form the first active material layer 120 to occupy alarger area than the second active material layer 220. In this case, thelayer disposition unit 630 may be used to dispose the second activematerial layer 220 to be within the area of the first active materiallayer 120.

In other words, in the battery manufacturing method according toEmbodiment 6, in the second-active-material-layer formation step S1210,the second-electrode-layer formation unit 620 may be used to form thesecond active material layer 220 to occupy a smaller area than the firstactive material layer 120.

In this case, in the layer disposition step S1310, the layer dispositionunit 630 may be used to dispose the first active material layer 120 soas to be outside of the area of the second active material layer 220.

The above-described manufacturing apparatus or manufacturing methodenables suppression of precipitation of metal (for example, lithium) onthe first active material layer 120. This prevents short circuitsbetween the first electrode layer 100 and the second electrode layer 200due to precipitation of metal.

Incidentally, in Embodiment 6, as illustrated in FIG. 24, thesecond-active-material-layer formation step S1210 and thesecond-solid-electrolyte-layer formation step S1220 may be performedafter the first-active-material-layer formation step S1110 and thefirst-solid-electrolyte-layer formation step S1120.

Alternatively, the second-active-material-layer formation step S1210 andthe second-solid-electrolyte-layer formation step S1220 may be performedbefore the first-active-material-layer formation step S1110 and thefirst-solid-electrolyte-layer formation step S1120.

Alternatively, the second-active-material-layer formation step S1210 andthe second-solid-electrolyte-layer formation step S1220 may be performedconcurrently with the first-active-material-layer formation step S1110and the first-solid-electrolyte-layer formation step S1120.

Hereinafter, a specific example of the battery manufacturing methodaccording to Embodiment 6 will be described.

FIG. 25 illustrates an example of the first-active-material-layerformation step S1110 and the first-solid-electrolyte-layer formationstep S1120.

On the first current collector 110 prepared, the first active materiallayer 120 is formed. For example, a coating material paste provided bykneading an active material (and other materials) and a predeterminedsolvent is applied to the first current collector 110 with a coatingapparatus, for example, (and may further be dried). At this time, thefirst active material layer 120 is formed to be in contact with thefirst current collector 110, and to occupy a smaller area than the firstcurrent collector 110 (first-active-material-layer formation stepS1110). Thus, the first active material layer 120 is formed on the firstcurrent collector 110 such that the first current collector 110 isexposed around the first active material layer 120.

On the first current collector 110 having the first active materiallayer 120 thereon, the first solid electrolyte layer 130 is formed. Forexample, a coating material paste provided by kneading a solidelectrolyte (and other materials) and a predetermined solvent is appliedto the first active material layer 120 and the first current collector110 with a coating apparatus, for example, (and may further be dried).At this time, the first solid electrolyte layer 130 is formed to occupythe same area as the first current collector 110(first-solid-electrolyte-layer formation step S1120). Thus, the firstsolid electrolyte layer 130 is formed on the exposed first currentcollector 110 to cover the first active material layer 120. Thus, thefirst electrode layer 100 (for example, an electrode plate) is formed.

FIG. 26 illustrates an example of the second-active-material-layerformation step S1210 and the second-solid-electrolyte-layer formationstep S1220.

On the second current collector 210 prepared, the second active materiallayer 220 is formed. For example, a coating material paste provided bykneading an active material (and other materials) and a predeterminedsolvent is applied to the second current collector 210 with a coatingapparatus, for example, (and may further be dried). At this time, thesecond active material layer 220 is formed to be in contact with thesecond current collector 210, and to occupy a smaller area than thesecond current collector 210 (second-active-material-layer formationstep S1210). Thus, the second active material layer 220 is formed on thesecond current collector 210 such that the second current collector 210is exposed around the second active material layer 220. Incidentally, inthe example illustrated in FIG. 26, the second active material layer 220is formed to occupy a larger area than the first active material layer120 (in other words, to have a larger area than the first activematerial layer 120).

On the second current collector 210 having the second active materiallayer 220 thereon, the second solid electrolyte layer 230 is formed. Forexample, a coating material paste provided by kneading a solidelectrolyte (and other materials) and a predetermined solvent is appliedto the second active material layer 220 and the second current collector210 with a coating apparatus, for example, (and may further be dried).At this time, the second solid electrolyte layer 230 is formed to occupythe same area as the second current collector 210(second-solid-electrolyte-layer formation step S1220). Thus, the secondsolid electrolyte layer 230 is formed on the exposed second currentcollector 210 to cover the second active material layer 220. Thus, thesecond electrode layer 200 (for example, an electrode plate) is formed.

FIG. 27 illustrates an example of the layer disposition step S1310.

The first electrode layer 100 and the second electrode layer 200separately formed are placed to face each other with a conveyanceapparatus, for example. Subsequently, the first electrode layer 100 andthe second electrode layer 200 are brought into contact with each otherto thereby be disposed on each other. Thus, the first active materiallayer 120 faces the second active material layer 220 with the firstsolid electrolyte layer 130 and the second solid electrolyte layer 230therebetween (layer disposition step S1310).

A portion of the first solid electrolyte layer 130 and a portion of thesecond solid electrolyte layer 230, the portions being in contact witheach other, can be bonded together by a drying step or a press-bondingstep, for example.

Incidentally, in the layer disposition step S1310, the whole region of amain surface of the first solid electrolyte layer 130 and the wholeregion of a main surface of the second solid electrolyte layer 230 maybe brought into contact with each other (and then may be bondedtogether). Alternatively, a partial region of a main surface (forexample, a half or larger region of the main surface) of the first solidelectrolyte layer 130 and a partial region of a main surface (forexample, a half or larger region of the main surface) of the secondsolid electrolyte layer 230 may be brought into contact with each other(and then may be bonded together).

FIG. 28 is a flowchart illustrating a modification of the batterymanufacturing method according to Embodiment 6.

In Embodiment 6, as illustrated in FIG. 23, the battery manufacturingapparatus 6000 may further include a press unit 640.

The press unit 640 is configured to press the first electrode layer 100and the second electrode layer 200 that are disposed on each other, tothereby bond together the first solid electrolyte layer 130 and thesecond solid electrolyte layer 230.

In other words, as illustrated in FIG. 28, the battery manufacturingmethod according to Embodiment 6 may further include a press step S1410(Step d). Incidentally, the press step S1410 may be performed after thelayer disposition step S1310.

The press step S1410 is a step of pressing, with the press unit 640, thefirst electrode layer 100 and the second electrode layer 200 that aredisposed on each other, to thereby bond together (press-bond together)the first solid electrolyte layer 130 and the second solid electrolytelayer 230.

In the above-described manufacturing apparatus or manufacturing method,the first solid electrolyte layer 130 and the second solid electrolytelayer 230 are press-bonded together, to thereby achieve stronger bondingbetween the first solid electrolyte layer 130 and the second solidelectrolyte layer 230. The above-described manufacturing apparatus ormanufacturing method also enables a further reduction in the probabilityof short circuits due to pinholes that may be generated in the firstsolid electrolyte layer 130 and the second solid electrolyte layer 230.

FIG. 29 illustrates the schematic configuration of a batterymanufacturing apparatus 6100 according to Embodiment 6.

In the battery manufacturing apparatus 6100 according to Embodiment 6,the first-electrode-layer formation unit 610 includes afirst-solid-electrolyte-layer formation unit 611, and afirst-electrode-side cutting unit 612.

The first-solid-electrolyte-layer formation unit 611 is configured toform the first solid electrolyte layer 130 to be in contact with thefirst current collector 110 and the first active material layer 120.

The first-electrode-side cutting unit 612 is configured to cut the firstsolid electrolyte layer 130 and the first current collector 110 suchthat the first solid electrolyte layer 130 occupies the same area as thefirst current collector 110.

In the battery manufacturing apparatus 6100 according to Embodiment 6,the second-electrode-layer formation unit 620 includes asecond-solid-electrolyte-layer formation unit 621, and asecond-electrode-side cutting unit 622.

The second-solid-electrolyte-layer formation unit 621 is configured toform the second solid electrolyte layer 230 to be in contact with thesecond current collector 210 and the second active material layer 220.

The second-electrode-side cutting unit 622 is configured to cut thesecond solid electrolyte layer 230 and the second current collector 210such that the second solid electrolyte layer 230 occupies the same areaas the second current collector 210.

FIG. 30 is a flowchart illustrating a modification of the batterymanufacturing method according to Embodiment 6.

The battery manufacturing method illustrated in FIG. 30 is a batterymanufacturing method using the battery manufacturing apparatus 6100according to Embodiment 6. For example, the battery manufacturing methodillustrated in FIG. 30 is a battery manufacturing method performed inthe battery manufacturing apparatus 6100 according to Embodiment 6.

In the battery manufacturing method illustrated in FIG. 30, afirst-solid-electrolyte-layer formation step S1120 (Step a2) includes afirst-solid-electrolyte-layer formation step S1121 (Step a21) and afirst-electrode-side cutting step S1122 (Step a22).

The first-solid-electrolyte-layer formation step S1121 is a step offorming the first solid electrolyte layer 130, with thefirst-solid-electrolyte-layer formation unit 611, so as to be in contactwith the first current collector 110 and the first active material layer120.

The first-electrode-side cutting step S1122 is a step of cutting thefirst solid electrolyte layer 130 and the first current collector 110,with the first-electrode-side cutting unit 612, such that the firstsolid electrolyte layer 130 occupies the same area as the first currentcollector 110. The first-electrode-side cutting step S1122 is performedafter the first-solid-electrolyte-layer formation step S1121.

In the above-described manufacturing apparatus or manufacturing method,the simple cutting step is performed, so that the first solidelectrolyte layer 130 and the first current collector 110 occupy thesame area. This enables further simplification of and a reduction in thecosts for battery manufacturing steps.

Incidentally, in the battery manufacturing apparatus 6100 according toEmbodiment 6, the first-electrode-layer formation unit 610 may include afirst-active-material-layer formation unit 613. Thefirst-active-material-layer formation unit 613 is configured to form thefirst active material layer 120. Thus, in thefirst-active-material-layer formation step S1110, thefirst-active-material-layer formation unit 613 may be used to form thefirst active material layer 120.

In the battery manufacturing apparatus 6100 according to Embodiment 6,the second-electrode-layer formation unit 620 may include asecond-active-material-layer formation unit 623. Thesecond-active-material-layer formation unit 623 is configured to formthe second active material layer 220. Thus, in thesecond-active-material-layer formation step S1210, thesecond-active-material-layer formation unit 623 may be used to form thesecond active material layer 220.

FIG. 31 illustrates an example of the first-solid-electrolyte-layerformation step S1121 and the first-electrode-side cutting step S1122.

On the first current collector 110 having the first active materiallayer 120 thereon, the first solid electrolyte layer 130 is formed. Forexample, a coating material paste provided by kneading a solidelectrolyte (and other materials) and a predetermined solvent is appliedto the first active material layer 120 and the first current collector110 with a coating apparatus, for example, (and may further be dried).At this time, the first solid electrolyte layer 130 is formed to occupya smaller area than the first current collector 110(first-solid-electrolyte-layer formation step S1121).

The first current collector 110 having the first solid electrolyte layer130 thereon is cut with a cutting apparatus, for example. The firstsolid electrolyte layer 130 and the first current collector 110 are cut(for example, cut at positions C11 and C12). As a result, the firstsolid electrolyte layer 130 occupies the same area as the first currentcollector 110 (first-electrode-side cutting step S1122). Thus, the firstelectrode layer 100 (for example, an electrode plate) is formed.

Incidentally, in the first-electrode-side cutting step S1122, the firstcurrent collector 110 and the first solid electrolyte layer 130 may besimultaneously punched out to achieve the cutting. In this case, thefour side edges of the first current collector 110 and the first solidelectrolyte layer 130 may be simultaneously cut off.

Incidentally, in the first-electrode-side cutting step S1122, cuttingmay be performed such that the first electrode layer 100 has a mainsurface having an area and a shape that are the same as the area and theshape of a main surface of the second electrode layer 200.

In the battery manufacturing method illustrated in FIG. 30, asecond-solid-electrolyte-layer formation step S1220 (Step b2) includes asecond-solid-electrolyte-layer formation step S1221 (Step b21) and asecond-electrode-side cutting step S1222 (Step b22).

The second-solid-electrolyte-layer formation step S1221 is a step offorming the second solid electrolyte layer 230, with thesecond-solid-electrolyte-layer formation unit 621, so as to be incontact with the second current collector 210 and the second activematerial layer 220.

The second-electrode-side cutting step S1222 is a step of cutting thesecond solid electrolyte layer 230 and the second current collector 210,with the second-electrode-side cutting unit 622, such that the secondsolid electrolyte layer 230 occupies the same area as the second currentcollector 210. The second-electrode-side cutting step S1222 is performedafter the second-solid-electrolyte-layer formation step S1221.

In such a configuration, the simple cutting step is performed, so thatthe second solid electrolyte layer 230 and the second current collector210 occupy the same area. This enables further simplification of and areduction in the costs for battery manufacturing steps.

FIG. 32 illustrates an example of the second-solid-electrolyte-layerformation step S1221 and the second-electrode-side cutting step S1222.

On the second current collector 210 having the second active materiallayer 220 thereon, the second solid electrolyte layer 230 is formed. Forexample, a coating material paste provided by kneading a solidelectrolyte (and other materials) and a predetermined solvent is appliedto the second active material layer 220 and the second current collector210 with a coating apparatus, for example, (and may further be dried).At this time, the second solid electrolyte layer 230 is formed to occupya smaller area than the second current collector 210(second-solid-electrolyte-layer formation step S1221).

The second current collector 210 having the second solid electrolytelayer 230 thereon is cut with a cutting apparatus, for example. Thesecond solid electrolyte layer 230 and the second current collector 210are cut (for example, cut at positions C21 and C22). As a result, thesecond solid electrolyte layer 230 occupies the same area as the secondcurrent collector 210 (second-electrode-side cutting step S1222). Thus,the second electrode layer 200 (for example, an electrode plate) isformed.

Incidentally, in the second-electrode-side cutting step S1222, thesecond current collector 210 and the second solid electrolyte layer 230may be simultaneously punched out to achieve the cutting. In this case,the four side edges of the second current collector 210 and the secondsolid electrolyte layer 230 may be simultaneously cut off.

Incidentally, in the second-electrode-side cutting step S1222, cuttingmay be performed such that the second electrode layer 200 has a mainsurface having an area and a shape that are the same as the area and theshape of a main surface of the first electrode layer 100.

Incidentally, in the above-described manufacturing method, in thefirst-electrode-side cutting step S1122, cutting may be performed suchthe first rounded portion 140 (or the first electrode layer 100) has thesame shape as any one of the above-described shapes in Embodiments 1 to5. Thus, the first electrode layer 100 including the first roundedportion 140 is formed.

In the above-described manufacturing method, in thesecond-electrode-side cutting step S1222, cutting may be performed suchthat the second rounded portion 240 (or the second electrode layer 200)has the same shape as any one of the above-described shapes inEmbodiments 1 to 5. Thus, the second electrode layer 200 including thesecond rounded portion 240 is formed.

The third electrode layer 300 including the third rounded portion 340and the fourth electrode layer 400 including the fourth rounded portion440 can also be formed by the same cutting method as above.

A different region may be cut off from each electrode layer such thatthe electrode layer has a main surface of a different size. Thus, therounded portions of the electrode layers can be formed to have the sameshape. As a result, the electrode layers can be disposed on each othersuch that, for example, the edge portions of the rounded portions of theelectrode layers are located to coincide with each other. Alternatively,the electrode layers can be formed to have the same shape. As a result,the electrode layers can be disposed on each other such that, forexample, the edge portions of the electrode layers are located tocoincide with each other.

Incidentally, in Embodiment 6, the first-electrode-layer formation unit610 (for example, the first-solid-electrolyte-layer formation unit 611and the first-active-material-layer formation unit 613) and thesecond-electrode-layer formation unit 620 (for example, thesecond-solid-electrolyte-layer formation unit 621 and thesecond-active-material-layer formation unit 623) may each include, forexample, a discharge mechanism (for example, a discharge port)configured to discharge a coating material (for example, an activematerial or a solid electrolyte material), a supply mechanism (forexample, a tank and a supply pipe) configured to supply the coatingmaterial to the discharge mechanism, a movement mechanism (for example,a roller) configured to move a coating target or the like, and a pressmechanism (for example, a press platform and a cylinder) configured toperform compression. These mechanisms may be appropriately selected frompublicly known apparatuses and members.

In Embodiment 6, the first-electrode-side cutting unit 612 and thesecond-electrode-side cutting unit 622 may each include, for example, acutting mechanism (for example, a die punch apparatus) configured to cuta cutting target, and a movement mechanism (for example, a roller)configured to move a cutting target or the like. These mechanisms may beappropriately selected from publicly known apparatuses and members.

In Embodiment 6, the layer disposition unit 630 may include, forexample, a conveyance mechanism (for example, a roller) configured toconvey the first electrode layer 100 and the second electrode layer 200to be disposed on each other. The mechanism may be appropriatelyselected from publicly known apparatuses and members.

In Embodiment 6, the press unit 640 may include, for example, a pressmechanism (for example, a press platform and a cylinder) configured tocompress the multilayer body including the first electrode layer 100 andthe second electrode layer 200, and a movement mechanism (for example, aroller) configured to move the first electrode layer 100 and the secondelectrode layer 200 to be pressed. These mechanisms may be appropriatelyselected from publicly known apparatuses and members.

The battery manufacturing apparatus according to Embodiment 6 mayfurther include a control unit 650. The control unit 650 is configuredto control operations of the first-electrode-layer formation unit 610(for example, the first-solid-electrolyte-layer formation unit 611 andthe first-electrode-side cutting unit 612), the second-electrode-layerformation unit 620 (for example, the second-solid-electrolyte-layerformation unit 621 and the second-electrode-side cutting unit 622), thelayer disposition unit 630, and the press unit 640.

The control unit 650 may be constituted by, for example, a processor anda memory. The processor may be, for example, a CPU (Central ProcessingUnit) or an MPU (Micro-Processing Unit). In this case, the processor maybe configured to read out and execute a program stored in the memory, tothereby perform a control method (battery manufacturing method)according to the present disclosure.

Embodiment 7

Hereinafter, Embodiment 7 will be described. Some descriptionsoverlapping any of those described in Embodiments 1 to 6 above will beappropriately omitted.

FIG. 33 illustrates the schematic configuration of a batterymanufacturing apparatus 7000 according to Embodiment 7.

The battery manufacturing apparatus 7000 according to Embodiment 7includes a first-electrode-layer formation unit 710, asecond-electrode-layer formation unit 720, a layer disposition unit 730,and a cutting unit 760.

The first-electrode-layer formation unit 710 is configured to form thefirst electrode layer 100.

The first-electrode-layer formation unit 710 is configured to form thefirst active material layer 120 to be in contact with the first currentcollector 110 and to occupy a smaller area than the first currentcollector 110.

The first-electrode-layer formation unit 710 is configured to form thefirst solid electrolyte layer 130 to be in contact with the firstcurrent collector 110 and the first active material layer 120.

The second-electrode-layer formation unit 720 is configured to form thesecond electrode layer 200.

The second-electrode-layer formation unit 720 is configured to form thesecond active material layer 220 to be in contact with the secondcurrent collector 210, and to occupy a smaller area than the secondcurrent collector 210.

The second-electrode-layer formation unit 720 is configured to form thesecond solid electrolyte layer 230 to be in contact with the secondcurrent collector 210 and the second active material layer 220.

The layer disposition unit 730 is configured to dispose the firstelectrode layer 100 and the second electrode layer 200 on each other.Thus, the layer disposition unit 730 is configured to dispose the firstactive material layer 120 to face the second active material layer 220with the first solid electrolyte layer 130 and the second solidelectrolyte layer 230 therebetween.

The cutting unit 760 is configured to cut the first solid electrolytelayer 130 and the second solid electrolyte layer 230, and the firstcurrent collector 110 and the second current collector 210. Thus, thecutting unit 760 provides the first solid electrolyte layer 130occupying the same area as the first current collector 110, and providesthe second solid electrolyte layer 230 occupying the same area as thesecond current collector 210.

FIG. 34 is a flowchart illustrating a battery manufacturing methodaccording to Embodiment 7.

The battery manufacturing method according to Embodiment 7 is a batterymanufacturing method using the battery manufacturing apparatus 7000according to Embodiment 7. For example, the battery manufacturing methodaccording to Embodiment 7 is a battery manufacturing method performed inthe battery manufacturing apparatus 7000 according to Embodiment 7.

The battery manufacturing method according to Embodiment 7 includes afirst-active-material-layer formation step S2110 (Step e1), afirst-solid-electrolyte-layer formation step S2120 (Step e2), asecond-active-material-layer formation step S2210 (Step f1), asecond-solid-electrolyte-layer formation step S2220 (Step f2), a layerdisposition step S2310 (Step g), and a cutting step S2510 (Step h).

The first-active-material-layer formation step S2110 is a step offorming, with the first-electrode-layer formation unit 710, the firstactive material layer 120 to be in contact with the first currentcollector 110 and to occupy a smaller area than the first currentcollector 110.

The first-solid-electrolyte-layer formation step S2120 is a step offorming, with the first-electrode-layer formation unit 710, the firstsolid electrolyte layer 130 to be in contact with the first currentcollector 110 and the first active material layer 120. Thefirst-solid-electrolyte-layer formation step S2120 is performed afterthe first-active-material-layer formation step S2110.

The second-active-material-layer formation step S2210 is a step offorming, with the second-electrode-layer formation unit 720, the secondactive material layer 220 to be in contact with the second currentcollector 210 and to occupy a smaller area than the second currentcollector 210.

The second-solid-electrolyte-layer formation step S2220 is a step offorming, with the second-electrode-layer formation unit 720, the secondsolid electrolyte layer 230 to be in contact with the second currentcollector 210 and the second active material layer 220. Thesecond-solid-electrolyte-layer formation step S2220 is performed afterthe second-active-material-layer formation step S2210.

The layer disposition step S2310 is a step of disposing, with the layerdisposition unit 730, the first electrode layer 100 and the secondelectrode layer 200 on each other such that the first active materiallayer 120 faces the second active material layer 220 with the firstsolid electrolyte layer 130 and the second solid electrolyte layer 230therebetween. The layer disposition step S2310 is performed after thefirst-solid-electrolyte-layer formation step S2120 and thesecond-solid-electrolyte-layer formation step S2220.

The cutting step S2510 is a step of cutting, with the cutting unit 760,the first solid electrolyte layer 130 and the second solid electrolytelayer 230, and the first current collector 110 and the second currentcollector 210, such that the first solid electrolyte layer 130 occupiesthe same area as the first current collector 110, and the second solidelectrolyte layer 230 occupies the same area as the second currentcollector 210. The cutting step S2510 is performed after the layerdisposition step S2310.

In the above-described manufacturing apparatus or manufacturing method,the first electrode layer 100 and the second electrode layer 200 aredisposed on each other and then subjected to cutting. This facilitatesalignment between the first electrode layer 100 and the second electrodelayer 200. In addition, for example, the first current collector 110,the first solid electrolyte layer 130, the second current collector 210,and the second solid electrolyte layer 230 can be simultaneously cut. Asa result, the first current collector 110, the first solid electrolytelayer 130, the second current collector 210, and the second solidelectrolyte layer 230 are provided to occupy the same area. This enablesfurther enhancement of positional stability of the first currentcollector 110 and the second current collector 210, and a furtherreduction in the probability of contact between the first currentcollector 110 and the second current collector 210.

In addition, the above-described manufacturing apparatus ormanufacturing method enables a further reduction in the probability ofcontact between the first current collector 110 and the second currentcollector 210. Specifically, a portion between the first currentcollector 110 and the second current collector 210, which face eachother with the portion therebetween, is fixed with the first solidelectrolyte layer 130 and the second solid electrolyte layer 230. Forexample, even when the first current collector 110 and the secondcurrent collector 210 are constituted by thin films, the presence of thefirst solid electrolyte layer 130 and the second solid electrolyte layer230 enables the spacing between the first current collector 110 and thesecond current collector 210 to be maintained to have at least apredetermined distance (for example, equal to or longer than the totalthickness of the first solid electrolyte layer 130 and the second solidelectrolyte layer 230). This prevents the first current collector 110and the second current collector 210 from coming into close proximity toeach other. This prevents, for example, even when a plurality of batterycells are stacked, deformation of the first current collector 110 andthe second current collector 210. Thus, for example, even when aplurality of battery cells are stacked, short circuits are preventedbetween the first current collector 110 and the second current collector210. In addition, in another example that is an all-solid-state batterynot having any separator between the first electrode layer 100 and thesecond electrode layer 200, the risk of short circuits caused by directcontact between the first current collector 110 and the second currentcollector 210 is reduced.

In addition, the above-described manufacturing apparatus ormanufacturing method eliminates the necessity of an additional memberfor insulation between the first electrode layer 100 and the secondelectrode layer 200 (for example, an insulation spacer). This enablesfurther simplification of and a reduction in the costs for batterymanufacturing steps.

In addition, the above-described manufacturing apparatus ormanufacturing method provides a solid electrolyte layer in which thefirst solid electrolyte layer 130 and the second solid electrolyte layer230 are bonded together. This enables a reduction in the probability ofshort circuits due to pinholes that may be generated, for example,during manufacture, in the first solid electrolyte layer 130 and thesecond solid electrolyte layer 230.

In addition, in the above-described manufacturing apparatus ormanufacturing method, the simple cutting step is performed, so that thefirst current collector 110, the first solid electrolyte layer 130, thesecond current collector 210, and the second solid electrolyte layer 230occupy the same area. This enables further simplification of and areduction in the costs for battery manufacturing steps.

Incidentally, in the above-described manufacturing method, in thecutting step S2510, cutting may be performed such that rounded portionsof the electrode layers (or the electrode layers) have any one of theabove-described shapes in Embodiments 1 to 5. This enables manufactureof a stack battery in which the electrode layers including the roundedportions are disposed on each other.

The third electrode layer 300 including the third rounded portion 340and the fourth electrode layer 400 including the fourth rounded portion440 can also be formed by the same cutting method as above.

In the cutting step S2510, the rounded portions of the electrode layerscan be formed to have the same shape. As a result, the electrode layerscan be disposed on each other such that, for example, the edge portionsof the rounded portions of the electrode layers are located to coincidewith each other. Alternatively, the cutting step S2510 can provide theelectrode layers to have the same shape. As a result, the electrodelayers can be disposed on each other such that, for example, the edgeportions of the electrode layers are located to coincide with eachother.

Incidentally, in the battery manufacturing apparatus 7000 according toEmbodiment 7, the second-electrode-layer formation unit 720 may be usedto form the first active material layer 120 to occupy a larger area thanthe second active material layer 220. In this case, the layerdisposition unit 730 may be configured to dispose the second activematerial layer 220 to be within the area of the first active materiallayer 120.

In other words, in the battery manufacturing method according toEmbodiment 7, in the second-active-material-layer formation step S2210,the second-electrode-layer formation unit 720 may be used to form thesecond active material layer 220 to occupy a smaller area than the firstactive material layer 120.

In this case, in the layer disposition step S2310, the layer dispositionunit 730 may be used to dispose the first active material layer 120 soas to be outside of the area of the second active material layer 220.

Such a configuration enables suppression of precipitation of metal (forexample, lithium) on the first active material layer 120. This preventsshort circuits between the first electrode layer 100 and the secondelectrode layer 200 due to precipitation of metal.

Incidentally, as illustrated in FIG. 34, in Embodiment 7, thesecond-active-material-layer formation step S2210 and thesecond-solid-electrolyte-layer formation step S2220 may be performedafter the first-active-material-layer formation step S2110 and thefirst-solid-electrolyte-layer formation step S2120.

Alternatively, the second-active-material-layer formation step S2210 andthe second-solid-electrolyte-layer formation step S2220 may be performedbefore the first-active-material-layer formation step S2110 and thefirst-solid-electrolyte-layer formation step S2120.

Alternatively, the second-active-material-layer formation step S2210 andthe second-solid-electrolyte-layer formation step S2220 may be performedconcurrently with the first-active-material-layer formation step S2110and the first-solid-electrolyte-layer formation step S2120.

Hereinafter, a specific example of the battery manufacturing methodaccording to Embodiment 7 will be described.

FIG. 35 illustrates an example of the first-active-material-layerformation step S2110 and the first-solid-electrolyte-layer formationstep S2120.

On the first current collector 110 prepared, the first active materiallayer 120 is formed. For example, a coating material paste provided bykneading an active material (and other materials) and a predeterminedsolvent is applied to the first current collector 110 with a coatingapparatus, for example, (and may further be dried). At this time, thefirst active material layer 120 is formed to be in contact with thefirst current collector 110, and to occupy a smaller area than the firstcurrent collector 110 (first-active-material-layer formation stepS2110). Thus, the first active material layer 120 is formed on the firstcurrent collector 110 such that the first current collector 110 isexposed around the first active material layer 120.

On the first current collector 110 having the first active materiallayer 120 thereon, the first solid electrolyte layer 130 is formed. Forexample, a coating material paste provided by kneading a solidelectrolyte (and other materials) and a predetermined solvent is appliedto the first active material layer 120 and the first current collector110 with a coating apparatus, for example, (and may further be dried).At this time, the first solid electrolyte layer 130 is formed to occupya smaller area than the first current collector 110(first-solid-electrolyte-layer formation step S2120). Thus, on theexposed first current collector 110, the first solid electrolyte layer130 is formed to cover the first active material layer 120. Thus, thefirst electrode layer 100 (for example, an electrode plate) is formed.

FIG. 36 illustrates an example of the second-active-material-layerformation step S2210 and the second-solid-electrolyte-layer formationstep S2220.

On the second current collector 210 prepared, the second active materiallayer 220 is formed. For example, a coating material paste provided bykneading an active material (and other materials) and a predeterminedsolvent is applied to the second current collector 210 with a coatingapparatus, for example, (and may further be dried). At this time, thesecond active material layer 220 is formed to be in contact with thesecond current collector 210, and to occupy a smaller area than thesecond current collector 210 (second-active-material-layer formationstep S2210). Thus, the second active material layer 220 is formed on thesecond current collector 210 such that the second current collector 210is exposed around the second active material layer 220. Incidentally, inthe example illustrated in FIG. 36, the second active material layer 220is formed to occupy a larger area than the first active material layer120 (in other words, to have a larger area than the first activematerial layer 120).

On the second current collector 210 having the second active materiallayer 220 thereon, the second solid electrolyte layer 230 is formed. Forexample, a coating material paste provided by kneading a solidelectrolyte (and other materials) and a predetermined solvent is appliedto the second active material layer 220 and the second current collector210 with a coating apparatus, for example, (and may further be dried).At this time, the second solid electrolyte layer 230 is formed to occupya smaller area than the second current collector 210(second-solid-electrolyte-layer formation step S2220). Thus, on theexposed second current collector 210, the second solid electrolyte layer230 is formed to cover the second active material layer 220. Thus, thesecond electrode layer 200 (for example, an electrode plate) is formed.

FIG. 37 illustrates an example of the layer disposition step S2310.

The first electrode layer 100 and the second electrode layer 200separately formed are placed to face each other with a conveyanceapparatus, for example. Subsequently, the first electrode layer 100 andthe second electrode layer 200 are brought into contact with each otherto thereby be disposed on each other. Thus, the first active materiallayer 120 is disposed to face the second active material layer 220 withthe first solid electrolyte layer 130 and the second solid electrolytelayer 230 therebetween (layer disposition step S2310).

FIG. 38 illustrates an example of the cutting step S2510.

The multilayer body including the first electrode layer 100 and thesecond electrode layer 200 is cut with a cutting apparatus, for example.The first solid electrolyte layer 130 and the second solid electrolytelayer 230, and the first current collector 110 and the second currentcollector 210 are cut (for example, cut at positions C31 and C32). As aresult, the first solid electrolyte layer 130 occupies the same area asthe first current collector 110, and the second solid electrolyte layer230 occupies the same area as the second current collector 210 (cuttingstep S2510).

A portion of the first solid electrolyte layer 130 and a portion of thesecond solid electrolyte layer 230, the portions being in contact witheach other, can be bonded together by a drying step or a press-bondingstep, for example.

Incidentally, in the cutting step S2510, the first current collector110, the first solid electrolyte layer 130, the second current collector210, and the second solid electrolyte layer 230 may be simultaneouslypunched out to achieve the cutting. In this case, the four side edges ofthe first current collector 110, the first solid electrolyte layer 130,the second current collector 210, and the second solid electrolyte layer230 may be simultaneously cut off.

Incidentally, in the layer disposition step S2310, the whole region of amain surface of the first solid electrolyte layer 130 and the wholeregion of a main surface of the second solid electrolyte layer 230 maybe brought into contact with each other (and then may be bondedtogether). Alternatively, a partial region of a main surface (forexample, a half or larger region of the main surface) of the first solidelectrolyte layer 130, and a partial region of a main surface (forexample, a half or larger region of the main surface) of the secondsolid electrolyte layer 230 may be brought into contact with each other(and then may be bonded together).

FIG. 39 is a flowchart illustrating a modification of the batterymanufacturing method according to Embodiment 7.

In Embodiment 7, as illustrated in FIG. 33, the battery manufacturingapparatus 7000 may further include a press unit 740.

The press unit 740 is configured to press the first electrode layer 100and the second electrode layer 200 that are disposed on each other, tothereby bond together the first solid electrolyte layer 130 and thesecond solid electrolyte layer 230.

In other words, as illustrated in FIG. 39, the battery manufacturingmethod according to Embodiment 7 may further include a press step S2410(Step p).

The press step S2410 is a step of pressing, with the press unit 740, thefirst electrode layer 100 and the second electrode layer 200 that aredisposed on each other, to thereby bond together (press-bond together)the first solid electrolyte layer 130 and the second solid electrolytelayer 230.

In the above-described manufacturing apparatus or manufacturing method,the first solid electrolyte layer 130 and the second solid electrolytelayer 230 are press-bonded together, to thereby achieve stronger bondingbetween the first solid electrolyte layer 130 and the second solidelectrolyte layer 230. The above-described manufacturing apparatus ormanufacturing method also enables a further reduction in the probabilityof short circuits due to pinholes that may be generated in the firstsolid electrolyte layer 130 and the second solid electrolyte layer 230.

Incidentally, as illustrated in FIG. 39, in the battery manufacturingmethod according to Embodiment 7, the cutting step S2510 may beperformed after the press step S2410.

In such a configuration, even when the press step causes expansion ofthe first solid electrolyte layer 130 and the second solid electrolytelayer 230, the cutting step subsequently performed enables removal ofthe expanded portions (excess portions) of the first solid electrolytelayer 130 and the second solid electrolyte layer 230. As a result, thefirst current collector 110, the first solid electrolyte layer 130, thesecond current collector 210, and the second solid electrolyte layer 230are provided to occupy the same area. This enables further enhancementof positional stability of the first current collector 110 and thesecond current collector 210, and a further reduction in the probabilityof contact between the first current collector 110 and the secondcurrent collector 210.

Incidentally, in Embodiment 7, the first-electrode-layer formation unit710 and the second-electrode-layer formation unit 720 may each include,for example, a discharge mechanism (for example, a discharge port)configured to discharge a coating material (for example, an activematerial or a solid electrolyte material), a supply mechanism (forexample, a tank and a supply pipe) configured to supply the coatingmaterial to the discharge mechanism, a movement mechanism (for example,a roller) configured to move a coating target or the like, and a pressmechanism (for example, a press platform and a cylinder) configured toperform compression. These mechanisms may be appropriately selected frompublicly known apparatuses and members.

In Embodiment 7, the layer disposition unit 730 may include, forexample, a conveyance mechanism (for example, a roller) configured toconvey the first electrode layer 100 and the second electrode layer 200to be disposed on each other. The mechanism may be appropriatelyselected from publicly known apparatuses and members.

In Embodiment 7, the press unit 740 may include, for example, a pressmechanism (for example, a press platform and a cylinder) configured tocompress the multilayer body including the first electrode layer 100 andthe second electrode layer 200, and a movement mechanism (for example, aroller) configured to move the first electrode layer 100 and the secondelectrode layer 200 to be pressed. These mechanisms may be appropriatelyselected from publicly known apparatuses and members.

In Embodiment 7, the cutting unit 760 may include, for example, acutting mechanism (for example, a die punch apparatus) configured to cuta cutting target, and a movement mechanism (for example, a roller)configured to move a cutting target or the like. These mechanisms may beappropriately selected from publicly known apparatuses and members.

The battery manufacturing apparatus 7000 according to Embodiment 7 mayfurther include a control unit 750.

The control unit 750 is configured to control operations of thefirst-electrode-layer formation unit 710, the second-electrode-layerformation unit 720, the layer disposition unit 730, the press unit 740,and the cutting unit 760.

The control unit 750 may be constituted by, for example, a processor anda memory. The processor may be, for example, a CPU (Central ProcessingUnit) or an MPU (Micro-Processing Unit). In this case, the processor maybe configured to read out and execute a program stored in the memory, tothereby perform a control method (battery manufacturing method)according to the present disclosure.

Incidentally, in Embodiments 6 and 7, the step of forming the firstelectrode layer 100 or the second electrode layer 200 may include a stepof dissolving an active material in a solvent (or mixing an activematerial with a dispersed binder) to prepare slurry. The slurry maycontain a solid electrolyte or a conductive additive. In this case, thestep of forming the first electrode layer 100 or the second electrodelayer 200 may be performed by a known coating method such as doctorblade coating, roll coater coating, bar coater coating, calenderprinting, or screen printing.

In Embodiments 6 and 7, the step of forming a solid electrolyte layermay include a step of dissolving a solid electrolyte in a solvent (ormixing a solid electrolyte with a dispersed binder) to prepare slurry.In this case, the step of forming the solid electrolyte layer may beperformed by a known coating method such as doctor blade coating, rollcoater coating, bar coater coating, calender printing, or screenprinting.

In Embodiments 6 and 7, the cutting step may be performed by a knowncutting method, such as a punching method (for example, die punching).

In Embodiments 6 and 7, the press step (for example, a press-bondingstep) may be performed by a known pressing method, such as uniaxialpressing, roll pressing, cold isostatic pressing (CIP), or hot isostaticpressing. Incidentally, when uniaxial pressing or roll pressing isemployed, a heating step may be performed.

In Embodiments 6 and 7, the phrase “the solid electrolyte layer isformed to occupy the same area as the current collector” means “thesolid electrolyte layer is formed to occupy substantially the same areaas the current collector except for the error unavoidably occurringduring the manufacture” (for example, the solid electrolyte layer isformed to have substantially the same shape as the current collectorexcept for the error unavoidably occurring during the manufacture).

In Embodiments 6 and 7, the solid electrolyte layer of one of theelectrode layers to be disposed may not be formed. In this case, thebattery according to Embodiment 3 is manufactured.

In Embodiments 6 and 7, in the layer disposition step, surfaces (to bedisposed on each other) of the electrode layers to be disposed may bechanged. For example, the electrode layers may be disposed on each othersuch that the current collectors are in contact with each other, tothereby manufacture the battery 4000 according to Embodiment 4. In thiscase, additional electrode layers may be disposed on both sides of thebattery to thereby manufacture the stack battery according to Embodiment4.

In Embodiments 6 and 7, on one of the main surfaces of a currentcollector, an active material layer and a solid electrolyte layer may beformed; and, on the other main surface, an electrode layer serving asthe counter electrode may be formed. Thus, the battery 5000 according toEmbodiment 5 is manufactured. In this case, additional electrode layersmay be disposed on both sides of the battery to thereby manufacture thestack battery according to Embodiment 5.

Incidentally, in the present disclosure, the first rounded portion 140may be “a portion formed to have a smaller radius than a corner portionof the first active material layer 120, the corner portion being thenearest to the first rounded portion 140” (in other words, a portionformed to have a larger curvature than a corner portion of the firstactive material layer 120, the corner portion being the nearest to thefirst rounded portion 140).

Specifically, for example, as illustrated in the example of FIG. 1, acorner portion of the first active material layer 120 (for example, anactive material layer formed to have a polygon shape), the cornerportion being the nearest to the first rounded portion 140, may be aportion having an angle of 90° or less (for example, a right angleportion or an acute angle portion). In this case, the first roundedportion 140 may be a portion formed by being cut to have a curve.

For example, as illustrated in the example of FIG. 3, the cornerportions of the first active material layer 120 (for example, an activematerial layer formed to have a polygon shape), the corner portionsbeing the nearest to the corresponding one of the first rounded portions(140 a, 140 b, 140 c, and 140 d), may be a portion having an angle of90° or less (for example, a right angle portion or an acute angleportion). In this case, each of the first rounded portions (140 a, 140b, 140 c, and 140 d) may be a portion formed by being cut to have acurve.

Incidentally, in the present disclosure, the first rounded portion 140may be “a portion having an angle larger than the angle of a cornerportion of the first active material layer 120, the corner portion beingthe nearest to the first rounded portion 140”.

Specifically, for example, as illustrated in the example of FIG. 2, acorner portion of the first active material layer 120 (for example, anactive material layer formed to have a polygon shape), the cornerportion being the nearest to the first rounded portion 140, may be aportion having an angle of 90° or less (for example, a right angleportion or an acute angle portion). In this case, the first roundedportion 140 may be a portion formed by being cut straight to have anangle of more than 90° only (for example, an obtuse angle).

For example, as illustrated in the example of FIG. 5C, the cornerportions of the first active material layer 120 (for example, an activematerial layer formed to have a polygon shape), the corner portionsbeing the nearest to the corresponding one of the first rounded portions(140 a, 140 b, 140 c, and 140 d), may be portions having an angle of 90°or less (for example, right angle portions or acute angle portions). Inthis case, each of the first rounded portions (140 a, 140 b, 140 c, and140 d) may be a portion formed by being cut straight to have an angle ofmore than 90° only (for example, an obtuse angle).

In such a case where the first rounded portion 140 is “a portion formedto have a smaller radius than a corner portion of the first activematerial layer 120, the corner portion being the nearest to the firstrounded portion 140” or “a portion having an angle larger than the angleof a corner portion of the first active material layer 120, the cornerportion being the nearest to the first rounded portion 140”, the firstactive material layer 120 can be disposed to occupy an area (forexample, a polygon area) as large as possible, provided that the area issmaller than that of the first current collector 110. This enables afurther increase in the energy density of the battery.

Incidentally, in the present disclosure, the second rounded portion 240may be “a portion formed to have a smaller radius than a corner portionof the second active material layer 220, the corner portion being thenearest to the second rounded portion 240” (in other words, a portionformed to have a larger curvature than a corner portion of the secondactive material layer 220, the corner portion being the nearest to thesecond rounded portion 240).

Specifically, for example, as illustrated in the example of FIG. 6, acorner portion of the second active material layer 220 (for example, anactive material layer formed to have a polygon shape), the cornerportion being the nearest to the second rounded portion 240, may be aportion having an angle of 90° or less (for example, a right angleportion or an acute angle portion). In this case, the second roundedportion 240 may be a portion formed by being cut to have a curve.

For example, as illustrated in the example of FIG. 7, the cornerportions of the second active material layer 220 (for example, an activematerial layer formed to have a polygon shape), the corner portionsbeing the nearest to the corresponding one of the second roundedportions (240 a, 240 b, 240 c, and 240 d), may be portions having anangle of 90° or less (for example, right angle portions or acute angleportions). In this case, each of the second rounded portions (240 a, 240b, 240 c, and 240 d) may be a portion formed by being cut to have acurve.

Incidentally, in the present disclosure, the second rounded portion 240may be “a portion having an angle larger than the angle of a cornerportion of the second active material layer 220, the corner portionbeing the nearest to the second rounded portion 240”.

Specifically, for example, a corner portion of the second activematerial layer 220 (for example, an active material layer formed to havea polygon shape), the corner portion being the nearest to the secondrounded portion 240, may be a portion having an angle of 90° or less(for example, a right angle portion or an acute angle portion). In thiscase, the second rounded portion 240 may be a portion formed by beingcut straight to have an angle of more than 90° only (for example, anobtuse angle).

For example, the corner portions of the second active material layer 220(for example, an active material layer formed to have a polygon shape),the corner portions being the nearest to the corresponding one of thesecond rounded portions (240 a, 240 b, 240 c, and 240 d), may beportions having an angle of 90 ⁰ or less (for example, right angleportions or acute angle portions). In this case, each of the secondrounded portions (240 a, 240 b, 240 c, and 240 d) may be a portionformed by being cut straight to have an angle more than 90° only (forexample, an obtuse angle).

In such a case where the second rounded portion 240 is “a portion formedto have a smaller radius than a corner portion of the second activematerial layer 220, the corner portion being the nearest to the secondrounded portion 240” or “a portion having a larger angle than a cornerportion of the second active material layer 220, the corner portionbeing the nearest to the second rounded portion 240”, the second activematerial layer 220 can be disposed to occupy an area (for example, apolygon area) as large as possible, provided that the area is smallerthan that of the second current collector 210. This enables a furtherincrease in the energy density of the battery.

Batteries according to the present disclosure are applicable to, forexample, all-solid-state lithium secondary batteries.

What is claimed is:
 1. A battery, comprising: a first electrode layer;and another electrode layer disposed on the first electrode layer andserving as a counter electrode for the first electrode layer, whereinthe first electrode layer includes a first current collector, a firstactive material layer, and a first solid electrolyte layer, the anotherelectrode layer includes another active material layer and another solidelectrolyte layer, the first active material layer is disposed to be incontact with the first current collector and to occupy a smaller areathan the first current collector, the another active material layer isdisposed to be in contact with the first current collector and to occupya smaller area than the first current collector, the first solidelectrolyte layer is disposed to be in contact with the first currentcollector and the first active material layer and to occupy the samearea as the first current collector, the another solid electrolyte layeris disposed to be in contact with the first current collector and theanother active material layer, and to occupy the same area as the firstcurrent collector, the first electrode layer includes a peripheralportion including a first rounded portion, and the another electrodelayer includes a peripheral portion including another rounded portion.2. The battery according to claim 1, wherein the first rounded portionand the another rounded portion have an identical shape, and the firstelectrode layer and the another electrode layer are disposed on eachother, and an edge portion of the first rounded portion and an edgeportion of the another rounded portion are located to coincide with eachother.
 3. The battery according to claim 2, wherein the first electrodelayer and the another electrode layer have an identical shape, and thefirst electrode layer and the another electrode layer are disposed oneach other, and an edge portion of the first electrode layer and an edgeportion of the another electrode layer are located to coincide with eachother.
 4. The battery according to claim 3, wherein the first electrodelayer has a shape including a corner portion, the corner portion of thefirst electrode layer includes the first rounded portion, the anotherelectrode layer has a shape including a corner portion, and the cornerportion of the another electrode layer includes the another roundedportion.
 5. The battery according to claim 4, wherein the firstelectrode layer has a polygon shape including a plurality of cornerportions, the plurality of corner portions of the first electrode layereach include the first rounded portion, the another electrode layer hasa polygon shape including a plurality of corner portions, and theplurality of corner portions of the another electrode layer each includethe another rounded portion.
 6. The battery according to claim 3,wherein the first electrode layer and the another electrode layer have acircular shape.
 7. The battery according to claim 1, further comprising:an additional electrode layer disposed on the first electrode layer andserving as a counter electrode for the first electrode layer, whereinthe first active material layer faces the additional electrode layerwith the first solid electrolyte layer therebetween.
 8. A batterycomprising: a first electrode layer; and another electrode layerdisposed on the first electrode layer and serving as a counter electrodefor the first electrode layer, wherein the first electrode layerincludes a first current collector, a first active material layer, and afirst solid electrolyte layer, the another electrode layer includesanother current collector, another active material layer, and anothersolid electrolyte layer, the first current collector and the anothercurrent collector are electrically connected to each other, the firstactive material layer is disposed to be in contact with the firstcurrent collector and to occupy a smaller area than the first currentcollector, the another active material layer is disposed to be incontact with the another current collector and to occupy a smaller areathan the another current collector, the first solid electrolyte layer isdisposed to be in contact with the first current collector and the firstactive material layer and to occupy the same area as the first currentcollector, the another solid electrolyte layer is disposed to be incontact with the another current collector and the another activematerial layer, and to occupy the same area as the another currentcollector, the first electrode layer includes a peripheral portionincluding a first rounded portion, and the another electrode layerincludes a peripheral portion including another rounded portion.
 9. Thebattery according to claim 8, wherein the first rounded portion and theanother rounded portion have an identical shape, and the first electrodelayer and the another electrode layer are disposed on each other, and anedge portion of the first rounded portion and an edge portion of theanother rounded portion are located to coincide with each other.
 10. Thebattery according to claim 9, wherein the first electrode layer and theanother electrode layer have an identical shape, and the first electrodelayer and the another electrode layer are disposed on each other, and anedge portion of the first electrode layer and an edge portion of theanother electrode layer are located to coincide with each other.
 11. Thebattery according to claim 10, wherein the first electrode layer has ashape including a corner portion, the corner portion of the firstelectrode layer includes the first rounded portion, the anotherelectrode layer has a shape including a corner portion, and the cornerportion of the another electrode layer includes the another roundedportion.
 12. The battery according to claim 11, wherein the firstelectrode layer has a polygon shape including a plurality of cornerportions, the plurality of corner portions of the first electrode layereach include the first rounded portion, the another electrode layer hasa polygon shape including a plurality of corner portions, and theplurality of corner portions of the another electrode layer each includethe another rounded portion.
 13. The battery according to claim 10,wherein the first electrode layer and the another electrode layer have acircular shape.
 14. The battery according to claim 8, furthercomprising: an additional electrode layer disposed on the firstelectrode layer and serving as a counter electrode for the firstelectrode layer, wherein the first active material layer faces theadditional electrode layer with the first solid electrolyte layertherebetween.